Thanks to all who have made suggestions. I was hoping to keep all the old
knobs,etc., except they are completely worn out. They "grind" when opening
and closing the doors and there's metal filings all over the linings of the
holes. I should have mentioned that sooner. Maybe the original owners of
this home must have hung 100lb laundry bags on them! lol...
It's at times like this I had my lathe. I would have turned a plug and
glued it in and then redrill the holes. I learned my lesson - NEVER sell a
Anyways guys, thanks for the great replies and, please, keep them coming if
you've ideas. I'm not in any big hurry. Gotta keep time open for golf,
Clamp a 1x2 across the existing "too small hole".
Mark the desired center point (inside the existing hole) and use the
proper hole saw.
I have installed a large number of retro-fits this way without
PS on second thought I believe I did use a longer pilot bit in the
I'm tellin ya to glue a tight fitting plug in the hole and redrill it. Way
faster than all the stuff everyone else is saying. It would have been done
by now. Really ,just plug the hole and redrill it out. Might need some bondo
though. Unless its a stain grade door. Use a flycutter/ plug cutter things
you use in a drill press.NOT a hole saw ! Cut it out oversze a wee bit and
rasp it to fit in the hole. As long as its flush to both sides or a little
over thickness. Sand it flush to the faces of the door stile , then plug the
little hole in the center of the plug then holesaw/ redrill the new hole
out. Works for me when I blow the hole, too big.Thish should take you about
1 hr to cut the plug/ fit and glue it in/Use 5 min Epoxy. Beltsand to flush
and redrill the hole.
2 1/2 hr job. EASY !
Here's a way it will take you 15 minutes...No Fuss...No filling..No Bogging
1) Mark out the centre of the existing hole in door out about 3" from the
hole both vertical & horizontal.
2) Take 2 pieces of scrap timber 4"x4"x 1/2" thick and mark a cross in the
centre, out to the edges
3) Cover the hole with the scrap timber..1 on either side ...line up the
cross on the timber with the centeline of the hole on the door and clamp
4) Useing a HOLE SAW, drill through the scrap...this will put the hole
centred on the old hole and the scrap timber will guide your hole saw into
the door. Repeat on from the other side and PRESTO..New hole centred on old
hole ...15 minutes tops
Professional results require professional tools. Check out your local
rental places and try to locate a jig for drilling holes for lockset
hardware. I have a jig made by Kwikset that I used when installing doors and
hardware many years ago. I bought a new door for a customer by using the
hole saw method and decided right then and there that the jig was not all
that expensive after all was said and done.
The jig adjusts for different thickness of doors and has an adjustment to
keep the jaws parallel as well. The bolt hole guide automatically centers
when changing thickness of doors. A kit will have a forstner bit for the
large hole and an auger bit for the bolt hole and require a 1/2 inch drill.
Once set, you can do a door in under 10 minutes and can save you lots of
time and endless amounts of frustration if you are doing a retrofit on the
Just one professional opinion. You might want to get another on the
possible "antique" value of your old hardware. Some old hardware is almost
worth its weight in gold to those who do high end restoration work! Good
luck with your project. ;)
"Eccentric by nature"
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