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I would like to replace the hardware on a front door. At first examination, the new lockset/handle will not be lining up with the holes from the 60 year old hardware.
My first thought is to use wood putty, fill the entire hole over several applications, let is cure properly, sand it smooth, and then bore out the new hole as needed. But is wood putty strong enough to fill a the holes large enough and deep enough for a lockset, and then after that be partially cut out a smaller and slightly offset holes for the new lockset?
If not, what product, or what method should I use?
Replies
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If there's no way to get new hardware to match up, I'd cut a wood plug to match the hole and use a high grade weather resistant glue or epoxy to glue it in. It'll be stronger than wood filler and unless the door is painted the patches will probably never match.
John
*I don't think you'd be happy with the wood putty results. We always use a wood patch and then hope it doesn't break loose when you re-drill it.Sometimes a large backplate can cover the old mortise.Good luck,Ed.
*Those repsonses were quick. Thanks! Yes it will be painted. The current hole is not a circle. It's better described as a hack job. To make the patch, Do I cut a clean circle cut around the hole and then cut a plug the exact same size? Or does the plug need to be ever so slightly larger and then glued and pounded in? Also, should I cut the plug with slightly thicker stock and sand it down after it has set?
*Cut a firm fitting plug but not so tight that you have to use an 8# sledge to set it. If the hole is ragged, you may be better off using a larger hole saw to clean up the cut (if the hole is round). Cut your plug either the same thickness or just a hair thicker and sand as you suggested. Use a good glue (like Gorilla...expensive but worth it) or an epoxy.Good luck,John
*Cut the hole a littel larger and clean and square. Now cut a plug that will fit snuggly into the hole. If you plan to stain the door, use a wood plug that contrasts the door nicley and center it so that it is evenly displaced around the new lockset area.First, dry fit your plug and then, if all fits well, coat the opening and plug with wood glue and set into hole. Finally, once this has set, I would drill through from the latch side of the door panel and set wooden dowels (with glue) all the way through the patch so that they grab the meat of the door on both sides of the patch. This will help keep that patch from breaking loose over time of the door be used constantly. Also the using of wooden dowels is wise because you can cut or drill trough them when cutting your new hardware holes.Pete
*I have used Minwax Wood Filler with very good results. It is a two part epoxy like “Bondo”. It dries quickly and can be then sanded and any voids refilled with a new batch. The warmer the temperature the faster it sets. It adheres good and can be drilled, etc. easily.
*If you have a router, a nice way to patch a door is to first plug the holes with glued-in wood pieces. Then take a piece of plywood, cut a rectangular hole out of the plywood, and use this as a template for routing a shallow mortise--about 4" x 8" often works. Then cut a piece of wood to match. Hard to describe, but it's a dutchman for the face of the door stile. Wood fillers over a large area eventually telegraph through the paint. Using the same species as the door guarantees a better-looking job, painted or not.
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I would like to replace the hardware on a front door. At first examination, the new lockset/handle will not be lining up with the holes from the 60 year old hardware.
My first thought is to use wood putty, fill the entire hole over several applications, let is cure properly, sand it smooth, and then bore out the new hole as needed. But is wood putty strong enough to fill a the holes large enough and deep enough for a lockset, and then after that be partially cut out a smaller and slightly offset holes for the new lockset?
If not, what product, or what method should I use?