Installing New Deadbolts - Router Forums
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post #1 of 20 (permalink) Old 09-17-2016, 07:28 AM Thread Starter
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Default Installing New Deadbolts

We just bought a new-to-us house, and we want to change the doorknobs and deadbolts. The existing hardware is made by Schlage, so we bought updated versions of the same Schlage models. Unfortunately, Schlage has change the design. The hole in the door for the deadbolt was originally 15/16". It's now 1".

How can I accurately enlarge a 15/16" hole to 1"? I sure don't want to destroy the doors learning how to do it. I realize I could make a jig that has a 1" hole (hopefully) in the right position to support a hole saw, but I'm hoping there's a better way.

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post #2 of 20 (permalink) Old 09-17-2016, 08:01 AM
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plug the hole w/ 15/16'' dowel and rebore...
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post #3 of 20 (permalink) Old 09-17-2016, 08:05 AM
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+1 what Stick said. Better than trying to make a jig.

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post #4 of 20 (permalink) Old 09-17-2016, 08:20 AM
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Another option would be to lay a template with a 1" hole over the 15/16" hole and use a flush trim bit in a router. Bearing would ride on the 1" template hole and increase the size of the hole in the door.
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post #5 of 20 (permalink) Old 09-17-2016, 08:32 AM
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Originally Posted by JIMMIEM View Post
Another option would be to lay a template with a 1" hole over the 15/16" hole and use a flush trim bit in a router. Bearing would ride on the 1" template hole and increase the size of the hole in the door.
And do it in two steps. With the door being (usually) 1-3/4" thick, start with a template and bit with a top-mounted bearing and open up one side. Switch to a bit with a bottom-mounted bearing and cut from the other side, using the new hole on the first side as a guide. Just make sure that you get the template lined up correctly with the hole in the edge of the door.
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post #6 of 20 (permalink) Old 09-17-2016, 10:35 AM
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Mark the exact size on the face and use a drill with sanding drum or rasp to grind to final size. It doesn't have to be perfect, as long as the lock doesn't slop around in the hole it will be fine.

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post #7 of 20 (permalink) Old 09-17-2016, 10:44 AM
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I would use a small drum sander on a DREMEL tool. you are only talking about 1/16" wall to remove. Shouldn't take a lot, and it doesn't need to be perfect. If the new deadbolt slides through the hole, you're golden!

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post #8 of 20 (permalink) Old 09-17-2016, 10:51 AM
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Mike, you might want to make life easy and see if you can rent a Kwikset installation jig. I can't count the number of locks and deadbolts I have installed with mine. The jig is self centering with perfect results every time. Just a thought.

By the way the Schlage locks are a very good choice. They have a built in Federal Fire Function that always allows you to turn the knob even when locked to escape quickly.
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post #9 of 20 (permalink) Old 09-18-2016, 01:59 AM
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I was successful with exactly the same problem. I took a 1 inch drill bit attached to a Milescraft-like portable drill guide. I centered the bit and drilled. It worked perfectly.

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post #10 of 20 (permalink) Old 09-18-2016, 09:16 AM
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I will offer KISS...

Round file or half round rasp...after all, you only need to remove about 1/32 around the hole...precision is not necessary...when it fits, stop...

If you were doing a bunch of 'em, I'd go the higher tech routes...

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