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Old 09-24-2008, 08:40 PM   #1
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got a hole needs filling

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There is this gap in my dead bolt. I am very certain that a previous owner replaced the one that was there with this one.
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You can see the same gap on the backside of the door too.
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This is what the strike looks like. The dead bolt works fine, so this is why I am hesitant to fix it. I see that there is a plastic washer or spacer between the dead bolt and the skin of the door. It is close to the same thickness as the alclad I have. I was thinking of cutting out a ring and putting it where the plastic washer or spacer is. I could then rivet the ring into place and make the nasty looking gap go away. Might even dress it up a bit. Does anyone have any thoughts on this?
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Old 09-24-2008, 08:58 PM   #2
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Sounds good to me, or you could just reskin the door
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Old 09-24-2008, 08:59 PM   #3
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Hmmmmm. . .

Most of these deadbolts have a selectable backset, either 2 3/8" or 2 3/4". It looks like the hole was made for a 2 3/4" backset, but the deadbolt was installed with the 2 3/8" setting.

Something to check before you cut metal.
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Old 09-24-2008, 09:08 PM   #4
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Gaps to fill

Frank-

I have the same problem. I didn't plan to get to it until I rebuild the door this winter.

I was planning to use a hole saw to cut two pieces of plywood, then chuck a bit of scrap aluminum between them and turn it to make an oversized washer that looked pretty on the outer edge. I could then drill a not-so-pretty center hole and vulkem it inside the lock, showing only the good parts.

I kinda liked the washer idea rather than extra rivets. If you can't buck, it is just not worth it.

If you want, I'll make an extra 1 or 2 at the same time.

John
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Old 09-24-2008, 09:11 PM   #5
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Quote:
Originally Posted by markdoane View Post
Hmmmmm. . .

Most of these deadbolts have a selectable backset, either 2 3/8" or 2 3/4". It looks like the hole was made for a 2 3/4" backset, but the deadbolt was installed with the 2 3/8" setting.

Something to check before you cut metal.

Check with a good locksmith. They may have a solution.
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Old 09-24-2008, 10:52 PM   #6
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Filling hole

A nice bead of Vulkem would take care of that hole.

Andy
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Old 09-24-2008, 11:25 PM   #7
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Lock companies make different size Trim Rings that are used to hide over sized holes. Here is one site that has some. - Locksmith Supplies - Lock, Trim Rings
A good lock shop should have just what you need.
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Old 09-24-2008, 11:54 PM   #8
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Frank,

I would make a nice round trim plate out of alclad, take the deadbolt out, rivet new beauty ring on, and reinstall the deadbolt.

Simple, elegant, looks better than a bead of sealant.
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Old 09-25-2008, 01:03 AM   #9
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Two best choices?

Quote:
Originally Posted by azflycaster View Post
Lock companies make different size Trim Rings that are used to hide over sized holes. Here is one site that has some. - Locksmith Supplies - Lock, Trim Rings
A good lock shop should have just what you need.
Hi, I'm with azflycaster; Buy door lock trim rings. Simple, clean looking, and easy to install. Or go with Aerowood, rebuild the whole door and re-install the correct locks.
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Old 09-25-2008, 04:37 AM   #10
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Wow quick responses... thank you fellas.
I hang doors all the time, did a massive front door with $1400 lock set just yesterday. Working in wood and metal are vastly different and require a different process.
I initially thought that the back set was wrong, but it turns out a previous owner used the original parts of the throw bolt and only replaced the dead bolt assembly. I put it back together and left it for another day. I scratched my head and pointed it out at a few rallies to get some feed back.
I secondly thought about using vulkem. I actually got a tube out, rags and WD40 for clean up,... and got ready to caulk the gap. And then it dawned on me that that would look so incredibly non professional. It would be a big gray bead right at eye level. It would look like Uncle Philips bath tub all gooped up with caulk, trying desperately to keep the water from doing what water does. It just was not an option. I stopped and scratched my head some more.
I did not consider re skinning the door. I think it would be a shame to have Anna loose all those deep oxidation pits on the door surface. I polished and sanded and polished some more to make it look good. I even had to come to terms with her skin being "loved by the elements" while polishing that door. I would consider it, but not unless it was really necessary.
Now those beauty rings are the ticket... I think though, the name implies it must be a thing of beauty. I can only see fabricating one from Alclad as an option. Nothing wrong with a ring of rivets around the dead bolt, might even add a level of detail... visual interest. Stay tuned, I will post some photos of what I do. First thing is to buy a new forstner bit 2 1/8" for a perfect center hole.
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Old 09-25-2008, 07:54 AM   #11
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Frank,

You can make your payment for $50 to Steve's Trailer Works for the design idea.

Steve
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Old 09-25-2008, 09:26 AM   #12
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Wow quick responses... thank you fellas.
I hang doors all the time, did a massive front door with $1400 lock set just yesterday. Working in wood and metal are vastly different and require a different process.
I initially thought that the back set was wrong, but it turns out a previous owner used the original parts of the throw bolt and only replaced the dead bolt assembly. I put it back together and left it for another day. I scratched my head and pointed it out at a few rallies to get some feed back.
I secondly thought about using vulkem. I actually got a tube out, rags and WD40 for clean up,... and got ready to caulk the gap. And then it dawned on me that that would look so incredibly non professional. It would be a big gray bead right at eye level. It would look like Uncle Philips bath tub all gooped up with caulk, trying desperately to keep the water from doing what water does. It just was not an option. I stopped and scratched my head some more.
I did not consider re skinning the door. I think it would be a shame to have Anna loose all those deep oxidation pits on the door surface. I polished and sanded and polished some more to make it look good. I even had to come to terms with her skin being "loved by the elements" while polishing that door. I would consider it, but not unless it was really necessary.
Now those beauty rings are the ticket... I think though, the name implies it must be a thing of beauty. I can only see fabricating one from Alclad as an option. Nothing wrong with a ring of rivets around the dead bolt, might even add a level of detail... visual interest. Stay tuned, I will post some photos of what I do. First thing is to buy a new forstner bit 2 1/8" for a perfect center hole.
I think you should make the trim ring (from Alclad of course) using a special shape. A good buddy of mine made me a nice patch in the shape of The Great State Of Texas.

Maybe you could use the shape of Maryland?

-Marcus
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Old 09-25-2008, 10:38 AM   #13
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Marcus,

Do you know how little that would cover, and look really weird at that!

How about the Wheel of Dharma for our Buddhist friend.

Namaste!

Steve
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Old 09-25-2008, 10:42 AM   #14
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Good idea Steve!

Or how 'bout this one?

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