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Old 08-21-2011, 01:02 PM   #1
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Kwikset lever set install


I feel like the biggest dumba** that ever walked. I bought a bed/bath lever set. When I am installing it, the inner and outer halves will not slide together enough to fit the door thickness. The door is 1 3/8ths. I know I have installed 50 plus sets over the years and never had this before. The half round lever that goes through the door and the inside half slides onto seems to be too long? I can see it hitting the plastic piece that turns to lock the door. I have been beating my head against the door for an hour thinking I'm over looking something very simple, but I can't figure it out. Any help would be much appreciated.

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Old 08-21-2011, 02:02 PM   #2
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Kwikset lever set install


Could you hacksaw off a small portion of that stupid little piece that fits from one knob to the other?? and hopefully have a file with you???? or will you run into problems with the tongue and the knobs hitting each other?

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Old 08-21-2011, 02:58 PM   #3
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Kwikset lever set install


With both halves removed from the door, mated together, what is the measurement between the inside surfaces of the face plates?
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Old 08-21-2011, 04:08 PM   #4
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Kwikset lever set install


They were just shy of 2 inches between them.

I took a cut off wheel and whacked 3/4 of an inch off and made it work. Funny, I also bought a passage set and it was the same way. Cut it as well.

I was hesitating cutting them for over an hour assuming I was missing something. I finally said to heck with it and cut them. I have to get two more passage sets yet. If they are the same way I will apply the same procedure. I will tell the guy at the big box store about it.

Thanks for the replies!
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Old 08-21-2011, 04:14 PM   #5
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Kwikset lever set install


Glad you got it solved!!

And by the way the Big Box Store dude will not care!!!!!!!!!!

Always carry a hack saw, a brush and a sense of humor.
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Last edited by m1951mm; 08-21-2011 at 04:24 PM.
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Old 08-21-2011, 04:33 PM   #6
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Kwikset lever set install


Quote:
Originally Posted by m1951mm View Post
Glad you got it solved!!

And by the way the Big Box Store dude will not care!!!!!!!!!!

Always carry a hack saw, a brush and a sense of humor.
ROTFLOL.... Thanks
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Old 08-23-2011, 07:35 AM   #7
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Kwikset lever set install


When you buy the next ones, check the end of the box to be sure they weren't special ordered for a thick door. Somebody may have canceled a special order and the store bozos threw them on the shelf. The package should tell you the door thickness range.
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Old 08-23-2011, 10:12 AM   #8
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Kwikset lever set install


I'm guessing they were packaged wrong. The package said for 1 3/8ths door. Thanks
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Old 08-24-2011, 09:19 AM   #9
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Kwikset lever set install


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Could you hacksaw off a small portion of that stupid little piece that fits from one knob to the other?? and hopefully have a file with you???? or will you run into problems with the tongue and the knobs hitting each other?
These locks are meant for this thickness door. The issue is operator error.
You do not cut off pieces of the lock.
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Old 08-24-2011, 09:45 AM   #10
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Kwikset lever set install


Newer Quikset locksets will appear to be too long for the door thickness until you start to tighten the two screws that hold the inner and outer halves together.

As Ron6519 said, there is no need to cut anything with a hacksaw.
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Old 08-24-2011, 04:47 PM   #11
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If I had tightened them like that, the plastic base on the lock switch would have popped out and the metal piece would have stuck out of the handle by at least 1/4 inch.
I should have taken pictures.

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