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skooterpie 11-18-2007 03:29 PM

Plugging an entrydoor
Hello all,
I am in the process of replacing all of my deadbolts and handsets throughout the house and apparently the handset on the entry door has a 2 3/4 backset while the deadbolt is 2 3/8. I would like to keep everything uniform so I assume the best way to tackle the situation is to plug the hole and rebore for a 2 3/8. The door is a standard 1 3/4, and probably Fir as it is about 65 years old and definitely seasoned. Can anyone give me some tips on how to cut a 2 1/8 round plug. I think I'll be able to find some 1 3/4 stock although it will probably be poplar. It will get painted,rebored and pretty much covered by the new handset other than the 3/8 offset.
Any other tips would be greatly appreciated.

Sammy 11-18-2007 04:41 PM

What brand of hardware are you using?

Probably would be easier to get the backset you need versus plugging the hole.

skooterpie 11-18-2007 05:17 PM

thanks sammy but I really want the deadbolt and handset to line up vertically so they will look good!!!!

Sammy 11-18-2007 06:34 PM

If your door is painted, I would make up a jig and router your plug and hole from each side. Dont do one plug all the way thru.

Have you considered moving the other lock over a little to see if you can get it to the same backset?

The only other option would be an escutheon [plate] to cover the hole without plugging.

Kingfisher 11-18-2007 07:16 PM

buy a 2 1/4" hole saw, drill a hole in the new wood you found, use this plug for the patch, glue it in and then fill the pilot hole anyway you want:thumbsup: If the plug is a little to big set a few teeth in more then try agian have do this many times:thumbup:

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