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Help with oddball size door handles

PP1PP1 Posts: 332 Deckhand
Replacing the interior door handles on a house that was built in the mid 60s'. Normally I would just get some new ones at the local hardware store and replace as needed. Unfortunately the existing handles are smaller than the normal handles available today (at least the interior part is). That makes the hole in the door too small also. So my options are:

1. Find handles that fit
2. Replace the doors with "standard" holes
3. Make the holes in the door big enough to fit the larger handles that are readily available.

Option 1 is most appealing to me because it requires the least amount of work. Below are some pictures that help the explanation:

On the first two you can see where the screw posts from the old handle line up with a new handle. They are narrower.




The next three are all of the original handle and just to see if anyone may be able to identify the manufacturer.
"If the women don't find you handsome, they should at least find you handy." - Red Green
«1

Replies

  • PolarPolar Posts: 22,492 AG
    3. Make the holes in the door big enough to fit the larger handles that are readily available.
  • ResinheadResinhead Posts: 10,987 AG
    Please video and post the attempt to make existing hole larger. That should be a good one.

    I'd replace the existing with new slabs or prehung units.
  • GrizGriz Posts: 9,951 Admin
    They look like the old handles in my circa 1960's house. I had no issue with standard handles fitting and never heard of your problem.
    The early bird may get the worm, but the Second Mouse gets the cheese. SW

    :Griz
  • PolarPolar Posts: 22,492 AG
    Resinhead wrote: »
    Please video and post the attempt to make existing hole larger. That should be a good one.

    I'd replace the existing with new slabs or prehung units.

    just use a hole saw, right? :rotflmao
  • SchmidtySchmidty Posts: 6,806 Admiral
    I have done it with my industrial sized drill press and some clamps.....

    ...there is also "butcher plates" that can be used...

    Of course ....one could just break down and buy a new slab.....
  • PP1PP1 Posts: 332 Deckhand
    Griz wrote: »
    They look like the old handles in my circa 1960's house. I had no issue with standard handles fitting and never heard of your problem.

    Never had an issue with me before either.....it's weird. Some are in bad shape though and need to be replaced.
    "If the women don't find you handsome, they should at least find you handy." - Red Green
  • PP1PP1 Posts: 332 Deckhand
    Wifey thinks #3 would be easy with a hole saw and a hand held drill. Hopefully I don't have to edumacate her on why it really is not.
    "If the women don't find you handsome, they should at least find you handy." - Red Green
  • PolarPolar Posts: 22,492 AG
    I was kidding about that too btw after watching one of my techs yesterday who made a 2 inch hole in a piece of wood about rip his fingers off trying to center a 3 inch hole saw in the hole :rotflmao
  • ResinheadResinhead Posts: 10,987 AG
    6 panel door slab are less than $40 at HD.
  • S.S.TupperwareS.S.Tupperware Posts: 1,056 Officer
    Bore a new hole... EZPZ, get a 2 1/8 hole saw, problem solved...
  • Baits OutBaits Out Posts: 12,328 AG
    Had the same thing here a few years ago when we bought all new high security lock sets.

    When I saw the problem, hired a lock smith to do it. He had a special jig just to do this.

    It is all but impossible to increase a hole by an eight of an inch or so (on center) without
    a guide and matched hole saw. Specially in a steel clad door.

    A southeast Florida laid back beach bum and volunteer bikini assessor who lives on island time. 
  • gandrfabgandrfab Posts: 21,646 AG
    Resinhead wrote: »
    Please video and post the attempt to make existing hole larger. That should be a good one.

    I'd replace the existing with new slabs or prehung units.
    Polar wrote: »
    just use a hole saw, right? :rotflmao

    I can do this on a door, on a boat, it's a hole saw trade secret I'm not going to give away.
  • S.S.TupperwareS.S.Tupperware Posts: 1,056 Officer
    I will, bore a hole in a piece of 3/4 and clamp to the door... It's not rocket science.
  • gandrfabgandrfab Posts: 21,646 AG
    41p-lJZjR-L._SY300_.jpg

    But I have hole saws.
  • S.S.TupperwareS.S.Tupperware Posts: 1,056 Officer
    yeah throw that in a router, and go free hand, won't be pretty. Just buy a cheap jig from the depot.
  • TeamTekeTeamTeke Posts: 993 Officer
    As Tupperware said above, use the 2 1/8" hole saw to cut a jig out of 3/4" material. Clamp that to the door so the jig is centered on the existing hole. Be careful as you cut through the back side so it will not tear out the wood on that side. Just go slow and slight pressure. I am a builder with 38 years experience.
    Happiness is the journey, not the destination.
  • S.S.TupperwareS.S.Tupperware Posts: 1,056 Officer
    Well that means you would have to take the door off the hinges... I would CNC it with a laser if I had to take it down.
  • Look Out BelowLook Out Below Posts: 3,825 Moderator
  • S.S.TupperwareS.S.Tupperware Posts: 1,056 Officer
    Bunion buster ya clamp to the coffee table?
  • robertgrantrobertgrant Posts: 88 Greenhorn
    Easy fix they make a few different jigs to re drill.
    H depot has a plastic one with a 2 1/8 hole saw and
    1 inch hole saw. Get one of those and re drill both
    Holes.
  • Baits OutBaits Out Posts: 12,328 AG
    TeamTeke wrote: »
    As Tupperware said above, use the 2 1/8" hole saw to cut a jig out of 3/4" material. Clamp that to the door so the jig is centered on the existing hole. Be careful as you cut through the back side so it will not tear out the wood on that side. Just go slow and slight pressure. I am a builder with 38 years experience.

    Good do-it-yourselfer advice and the way to go if you have wood doors and a couple good clamps that won't move.

    Another hole saw story if steel clad doors.

    A southeast Florida laid back beach bum and volunteer bikini assessor who lives on island time. 
  • jad1097jad1097 Posts: 9,611 Admiral
    Easy fix they make a few different jigs to re drill.
    H depot has a plastic one with a 2 1/8 hole saw and
    1 inch hole saw. Get one of those and re drill both
    Holes.

    I've done it many times with one of the kits......easy......just go slow
  • seajay-1seajay-1 Posts: 4,736 Captain
    PP1 wrote: »
    Replacing the interior door handles on a house that was built in the mid 60s'. Normally I would just get some new ones at the local hardware store and replace as needed. Unfortunately the existing handles are smaller than the normal handles available today (at least the interior part is). That makes the hole in the door too small also. So my options are:

    1. Find handles that fit
    2. Replace the doors with "standard" holes
    3. Make the holes in the door big enough to fit the larger handles that are readily available.

    Option 1 is most appealing to me because it requires the least amount of work. Below are some pictures that help the explanation:

    On the first two you can see where the screw posts from the old handle line up with a new handle. They are narrower.




    The next three are all of the original handle and just to see if anyone may be able to identify the manufacturer.





    Standard 2-3/8 backset 2-1/8 bore.
    Any blister pack lock will work.
  • PP1PP1 Posts: 332 Deckhand
    Looks like it's probably gonna be hole saw attempt. I had figured I could use that with some clamps, finish nails, raw wood, and any other types of things I could fasten together to make it accurate (and more important reasonably safe) and everything, but was hoping to just buy some handles. Already got way too much time invested in this little project and I've got 4 or 5 to do this to.

    Thanks for the helpful (and the funny) suggestions. Just wish I could figure out a way to use the handy mans secret weapon. (See sig for reference)
    "If the women don't find you handsome, they should at least find you handy." - Red Green
  • It's a No Brainer.
    Yo've got 40 year old Interior Doors. Flush Slabs, probably 50 coats of paint on them and they look like Happy Days style.
    6 Panels and upgrade.
    Unless this is a Rental.
    Your Wife will love you long time...:grin
    Killin and Grillin :grin
  • ResinheadResinhead Posts: 10,987 AG
    It's a No Brainer.
    Yo've got 40 year old Interior Doors. Flush Slabs, probably 50 coats of paint on them and they look like Happy Days style.
    6 Panels and upgrade.
    Unless this is a Rental.
    Your Wife will love you long time...:grin

    Amen... I go through 5 or 10 a year in rentals.
  • stc1993stc1993 Posts: 10,588 AG
    Resinhead wrote: »
    Amen... I go through 5 or 10 a year in rentals.

    Me too, I've done so many in the last 15 yrs. I can hang one & install hardware pretty quick.
  • Finger MulletFinger Mullet Posts: 3,852 Officer
    Did you check on the web if you can find the original size used?
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