Enlarging a hole for a deadbolt

[Doug Kanter]

OK, wizards - here's a situation I can't find a good solution to. I have a Yale deadbolt in my back door, and want to replace with a KwikSet. The backset (from edge of door to center of hole) is correct for Kwikset, but the hole's size is too small. It's about 1-3/4", and the Kwikset requires

2-1/8". I've got the right size hole saw, but without solid wood for the guide bit, I can't see a way for the saw to work correctly. Using a saber saw is a possibility, I guess, but I wonder if there's something more elegant, as opposed to turning this into a cob job.

Anyone got a cool trick?

[C C]

Fill the hole with wood putty, let it set up and redrill with correct size hole saw Chuck

[Mark and Kim Smith]

How 'bout get a 3/4" thick piece of scrap. Make hole with the new hole saw. Clamp scrap into position over where you want bigger hole. Drill hole.

[Doug Kanter]

That's a lot of putty. Could take several applications, and a week or more for all of it to set up. Now I'm wondering about screwing a piece of scrap wood to one side of the door and using that as a target for the guide bit.

[Will]

Use a 1-3/4" hole saw as guide and piggy back a 2-1/8" hole saw on top. This trick I read it on a magazine this month.

[Bill Stock]

1) Cut a hole the old size (1-3/4") and glue the cutout in the hole.

2) Take a square scrap of wood. Draw a 1-3/4" circle with a compass. Make a pilot hole at the center. Line up the circle with the old door hole. Clamp the scrap in place. Drill the new hole using the scrap as your guide.

[Tom]

[Eric Ryder]

Bore the correct hole in a scrap of ply, clamp this where you want the hole and bore away. The scrap will guide the outside of the holesaw. For the best results, bore the skin from both faces in.

[Dan Lanciani]

| OK, wizards - here's a situation I can't find a good solution to. I have a | Yale deadbolt in my back door, and want to replace with a KwikSet. The | backset (from edge of door to center of hole) is correct for Kwikset, but | the hole's size is too small. It's about 1-3/4", and the Kwikset requires | 2-1/8". I've got the right size hole saw, but without solid wood for the | guide bit, I can't see a way for the saw to work correctly. Using a saber | saw is a possibility, I guess, but I wonder if there's something more | elegant, as opposed to turning this into a cob job. | | Anyone got a cool trick?

Starrett has a special "Oops" arbor (seriously, that's the name) that lets you use one hole saw as a pilot for a bigger hole saw. It has a 1/4" shank and threads for both saw sizes. I think you might be better off just clamping a piece of wood over the hole as others have suggested, though. When my locksmith did this he used his normal lock jig. Versions of that are available at home stores.

Dan Lanciani ddl@danlan.*com

[Dave Balderstone]

Cut a plug to fill the hole, glue it in place, then redrill. You'll even have a pilot hole.

djb

[Dave Balderstone]

Ooh! I like that better than plugging the existing hole!

[Sti©ky]

I used this method for several french doors. Worked like a charm and was dead easy.

[berkshire bill]

I buy rubber arbors for sanding drums. Press in a piece of tubing to act as a pilot bearing.

Bill

[Joe Fabeitz]

Once again, the solution to this was illustrated in the latest edition of "The Family Handyman".

Mount two hole saws on the same arbor. Slide the larger one on first so it will be closer to the drill chuck, then slide the 1 3/4" saw on. Tighten both, insert the smaller one in the existing hole, using it as a pilot.

[Doug Kanter]

Attach them both to the same arbor?

[Stormin Mormon]

Kwikset makes a drill jig for just this. I bought one about 15 years ago for my locksmith biz. And have made a pile of money with it. Call a local locksmith and pay him a lot of money.

Plan B is to take two pieces of thin plywood, and a couple C-clamps. Clamp plywood on both sides of the door. Use a carpenters square to mark where the hole oughta be, and drill with a hole saw. I personally can't encourage you to do this, cause it would deprive a brother locksmith of a house call.

[Stormin Mormon]

Might work -- but a lot of extra work.

[Bubba]

I've had the same problem replacing Dexter Locks with Baldwins. Our local Ace Hardware Store has a kit that they rent out. It contains a large metal jig that clamps to the door and a 2 1/8 inch forsner bit. Easy, fool proof and fast. Takes about 4 minutes. They rent it out for about $20 for a couple of hours and require a $200 deposit to make sure you use it and bring it back.

[firstjois]

[snip]

I must have seen it, too, but just can't remember where. Both attached to the same arbor, reminded me of an upsidedown wedding cake.

Josie

[willshak]

That's the best, and easiest, solution so far.