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Ironlight 03-01-2012 02:37 PM

Drilling out a larger hole for a new lock...
I'm replacing the lock on my front door (double deadbolt because the door has beveled glass panels in it). The existing hole is around 1 7/8" and the new lock needs a 2 1/8" hole. Is there some neat trick for centering the larger hole saw on the existing hole since you don't have the benefit of anything for the pilot bit to drill into?

I figured someone here might know a way I might never think of...

Daniel Holzman 03-01-2012 02:46 PM

You need to cut out a plug to fit the old hole. This would be 1-7/8 inch diameter, you may need to wrap a piece of paper around it to get it to fit tight in the hole. You use the plug to allow the pilot for the new hole to grab.

Ironlight 03-01-2012 02:59 PM

That means getting a new hole saw. ARGH I was just at the hardware store, lol.

Thanks Daniel, that sounds like a plan.

joecaption 03-01-2012 03:28 PM

Take a piece of OSB, Plywood, 1 X whatever you have laying around and hold it so it's flush with the side of the door. Draw a circle where the old hole is.
Find the center of that hole and mark it.
Bore the scrape piece with the 2-1/8" hole saw. Now just screw it to the door making sure it's centered with the old hole. Now bore your 2-1/8 hole using the scrape pieces as your saw guide.

HomeSealed 03-01-2012 03:58 PM

Thats a good idea Joe.... although I'd suggest clamps if you don't want screw holes in your door. :thumbsup:

joecaption 03-01-2012 04:25 PM

Quick grip clamps may woudl with out any damage. I forgot to add to put the screws where the knob trim would cover it up so no repairs would be needed.

HomeSealed 03-01-2012 04:42 PM

Right on.

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