How to repair damaged door cladding and seal gap?

[PotatoDuck]

Hi all, 

I recently had a locksmith out to install a smart lock on an exterior door but unfortunately they've caused a bit of damage to the door cladding during the install where a portion of the cladding has 'caved in'. There is also a gap between the actual smart lock and the door where I'm concerned dust/water might get in. 

I'm thinking I need to:

• Fill in the 'caved in' segment of door with some wood filler, sand it, apply a primer and repaint it to match existing cladding
• Apply a silicone bead around the whole door lock to ensure there's no longer a gap for water/dust ingress (thinking some sort of clear silicone so its not too obvious and something suitable for outdoor use?)

Does this sound like the right solution and if so could I get some recommendations for appropriate products to use? It's an exterior door that gets a fair bit of sun and rain.

 Gap between door and lockGap between door and lockCaved in segment of claddingCaved in segment of cladding

Thanks!

[EricL]

Hello @PotatoDuck 

Welcome to the Bunnings Workshop community. It's sensational to have you join us, and thanks for sharing your question about your damaged door.

It appears that the front panel of the door has caved in and the locking mechanism is not sitting properly on the door surface. Can I please request for a photo that shows the door lock and the door assembly. Your photo shows the caved in section, but we need to see how badly damaged the rest of the door is and if it can still be repaired. Once we see how far the damage goes, we'll be able to offer recommendations whether if it can still be repaired or if it will need to be replaced.

If you have any other questions we can help with, please let us know.

Eric

[PotatoDuck]

Thanks for responding Eric!

Please find additional photos as requested - let me know your thoughts.

[MitchellMc]

Hi @PotatoDuck,

From the photos, it looks like the damage to your door could have potentially been caused by over-tightening the lock screws, which has crushed the front skin of the door. This could happen on hollow-core doors, as they don’t have the same solid structure as a standard external solid-core door. Unfortunately, this type of damage isn’t something that wood filler alone can fully fix. While it might improve the appearance slightly, it could end up looking worse than the current damage.

The first step, if you haven't already, is to speak with your installer about the issue and have the lock loosened so it’s no longer causing further damage. From there, it’s worth considering whether the current door is suitable for this type of smart lock. A solid-core exterior door is typically better for these installations, as it can properly support the lock without crushing. From the images, it also looks like there may be an additional timber piece attached to the door; if that was added to accommodate the lock, it may not provide enough structural support, contributing to the current issues.

At this stage, the most reliable solution may be to replace the door with one of the correct thickness and structure for your lock, which will prevent ongoing problems. Once a suitable door is in place, you can address sealing gaps with a clear, exterior-grade silicone around the lock to prevent dust and water ingress. 

You might like to take advantage of our Door Installation Service and Door Lock Installation Service.

Please let me know if you have any questions.

Mitchell