My wife has been talking about replacing our front door with something nicer for several years. We are both strong proponents of recycling so today when I came across a beautiful old solid oak door with leaded glass (already stripped) for $75, I got pretty excited.
Unfortunately, the measurements do not exactly match the existing door. The used door is 1 1/2" shorter and 1/8" narrower. Also, there are two 2" holes drilled in it. The deadbolt hole is not even close to where my existing deadbolt is located and it's too big. But the latch hole matches perfectly when measuring down from the top of the door so if I have someone build down the door frame, this could work.
Can a hole be filled in such a way that would not be very noticable with a clear coat finish?
Can a good carpenter modify the door frame so the door will look good and work well? What should be done about the missing 1/8" in width?