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How to fix door handles sagging and showing cutout holes?

Most door handles in our house are sagging a few mm causing the door cut out hole to be noticeably visible. I've tried removing all parts completely, cleaning, and oiling before installing and tightening again. For a week or so the gap isn't visible but sure enough the sag returns.

All door handles are the same. This appears to be the product https://www.bunnings.com.au/gainsborough-g4-series-satin-chrome-lianna-passage-lever-set_p4180322 or the bright chrome edition. The handles themselves operate normally, except one which has a spring squeak and needs a much larger range of motion to open.

How can I fix this permanently so that the gap either never becomes visible or that the gap is filled appropriately?

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Comments

MitchellMc

Hi @chickensoup64,

The issue is most likely because these handles are being retrofitted into existing door handle cutouts that are slightly oversized. The G4 series handles are fixed in place by two bolts that run from the flange on one side to the flange on the other. When the bolts are tightened, the flanges are drawn together, sandwiching and compressing the door — this is where the holding strength of the handle comes from. In your case, the holes cut in the door appear almost the same size as the flanges, so when the handle shifts even slightly, the cutout becomes visible. Because the flanges aren’t sitting fully on the door face but right on the edge of the hole, they can’t grip properly, and the handles keep loosening. Unfortunately, there’s no simple fix other than filling the current hole with a solid piece of timber and re-drilling correctly sized holes to match the flanges.

One other point — from the image below, it looks like both flanges might be on the same side of the door. If that’s how all of them are installed, that would explain why they aren’t gripping. Even if that’s not the case, the oversized holes remain the main cause. I've marked the flange that should be on the other side of the door.

Please let me know if you have any questions.

Mitchell

AlanM52

Hi @chickensoup64,

I have been there before and came up with a fix after going through my crates of lighting and plumbing stuff.

Don't know/remember where they came from but I found trim rings similar to below.

Screenshot 2025-08-14 124500.jpeg

Ask the workshop guys for further assistance and/or with handle in hand go for walkies in the plumbing section.

Cheers

chickensoup64

@MitchellMc what would be the right way to make a filler piece of wood and securing it in place to drill a new, smaller, bore hole?

I've got some more photos just now which might assist. These are all from the same door this time. The measurements suggest the current bore hole probably isn't too big?

@AlanM52 good to know those exist! I was looking for similar plates/rosettes to put on other doors which are missing, maybe I'll need to change the entire house.

I don't think they will cover the gap though as it is still visible with the current covers.

AlanM52

https://www.workshop.bunnings.com.au/discussion/comment/55918#Comment_55918

@chickensoup64,

OK... I would still be chasing something like that.

Cheers

EricL

https://www.workshop.bunnings.com.au/discussion/comment/55918#Comment_55918

Hello @chickensoup64

To reduce the size of the hole and provide more area for the door handle to sit on, I suggest cutting a piece of timber that is as thick as the door and be at least 15mm to 20mm tall. Pre-drill the filler and fix it to the top of the door cut out with screws in combination with timber adhesive. Allow the adhesive to cure and do a test fit to see if improves the door handles holding position. If it firms up the door handles position, I suggest filling the gap between the door and timber filler then painting it to match the doors finish. Once the paint is dry you can re-install the door knob.

I propose observing the handles behaviour for the next few weeks and see if it stays still and does not loosen up. If the repair works you can then apply it to the rest of the door sets that are loose.

If you need further assistance, please let us know.

Eric

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