I went to replace an old Dexter lockset handle on front door with a Schlage unit. What I found after getting the old set off was the main hole was 1 5/8" and the new units seem to call for a larger 2 1/8".

Is there a good way to redrill a hole in existing door?

Thanks.

Keith

 

Sure. Take a couple pieces of wood, like a 1x4, put one on each side of the door, then clamp them to the door. This will give you some fresh wood to start the hole, and will provide a guide around the outside of the hole saw. Drill slowly as the hole saw starts into the door.

Just be sure you start the new hole in the right location, with the proper amount of backset from the door edge. (2 3/8 or 2 3/4).

 

Hello Keith,

xsleeper is right. The critical part is making sure you have the correct backset, and highth. Centering is not easy, but it can be done in this manner. Remember to measure twice, and cut once. Good luck, and please keep us updated?

cuedude

 

XSleeper, are hole saws deep enough to go through 3 1/4" (1 3/4" + 1 1/2")? I've never done this but I was told by a carpenter to cut a plug (1 5/8") and jamb it into the existing hole and then drill the correct size hole. What do you think?

 

The hole saws I have are about 2 to 2 1/2" deep. I think most are like that. When drilling through something thick consisting of various layers (like drilling through a wall), you have to remove the waste, then keep drilling.

So following my suggested method, you would drill through the first 3/4, then remove the waste. Then you would be able to drill through the door without any problem. Using 2 pieces (one clamped to the back) helps avoid tearout. Additionally, if you used a pilot bit to mark the center of the hole and drilled all the way through, you'd be able to come at it from both sides, which is often a good technique that helps you avoid tearout (splinters). It also sometimes makes the plug easier to get out of the hole saw.

Cutting a 1 5/8" plug would probably work too, but a 1 5/8" hole saw makes a plug that is about 1 1/2" and it would be sloppy in the hole and would not lead to starting a perfect hole. If you could make a plug that fit perfectly tight, then yes, that'd work good.

Clamping scraps onto the door and redrilling is easiest to me. It works perfectly.

 

Rockler has a special hole saw arbor for stacking hole saws of the existing and desired sizes to redrill:

http://www.rockler.com/product.cfm?O...GBHHDADADADBDB

 

Hi, The way I do it is I cut the 2 1/8 hole in the scrap wood first then I center it by eye and clamp it to the door, cut about half way through then put the scrap wood on the other side and finish the cut.If you are changing the backset draw some center lines on the door to guide you.
Good Luck Woodbutcher

 

another alternative is to just get a bore kit from a local hardware store. they come w/ a template that (usually) matches right up to schlage specs, and the hole saws to go along with it. they make them for metal and wood doors, so you just need to look carefully at which one your getting (they look almost identical)

 

I use Woodbutcher's method. Mark vertical and horizontal center lines on the scrap wood before cutting the hole. This will aid in aligning when clamping to the door. Good luck with your project.

 

Lace drilling is another method too, but will require some cleaning to get holes nice