How to attach a door handle through thin aluminium?

[Eloise-]

 

I’m trying to change the door handle on a sliding glass door. I’m having trouble with the strike plate though. When I screwed in with the provided screws it all lined up but it just wasn’t held in place at all. I’m wondering if it’s because the aluminium is so thin?

I’ve included a photo of the aluminium frame where I need to attach it, a photo of the strike plate being held in place and a third of the hole in the face plate where the screw goes through 

What are my options for something that will hold it in place? 

 

[Eloise-]

So I’m using the new screws that came with the handle. I do have the old screws too if it helps but they went into a different part of the frame (you can’t see the back of them once they were screwed in) and I wasn’t sure if that’s why they worked and mine didn’t. 

I screwed them in with a drill

The holes didn’t seem massively over sized but they weren’t biting into anything either so with any kind of movement to the strike plate they ended up falling about halfway out of the hole

The end was cut off but it is flat across rather than a pointed tip

[Eloise-]

I figured it would work originally but when I tried it the first time there wasn’t enough bite to hold them in place 

[JacobZ]

Hi @Eloise-,

Are you saying you tried the method @Nailbag mentioned of screwing it in with the provided screws and then grinding the protruding point off?

If that were the case, I would try using a larger diameter screw. Metal deforms when screws are driven through it, and if you are using the same hole with the same size screw, then it more or less needs to line up perfectly with the position the old screw was in for it to bite.

We're in the process of updating the screw listings on our website, so it is tough for me to point you directly to something suitable, but if you head in store and grab a sheet metal screw like these Buildex 8G x 18mm Self Tapping Sheet Metal Screws in a larger diameter to the one you currently have, then drive it into the existing hole before grinding off the tip, you might have more success.

Otherwise, mounting it to the timber on the right like @EricL mentioned, might be your best option.

Let me know what you think.

Jacob

[Eloise-]

Sorry no, I didn’t try grinding the ends of the screws off, would that help with them not having any bite? 

When I went in person yesterday I actually had those recommended to me but I wasn’t sure if there was enough metal left between the holes for them to work or if the two sets of holes were likely to merge together.

I’ve also never used them before so I wasn’t sure if I should use a drill or manual screwdriver with them 

[JacobZ]

Hi @Eloise-,

No, grinding the ends off wouldn't help with bite; it was just mentioned because the point of the screw will show on the other side of the aluminium frame, and it can be cut off if required.

What I am proposing is using a slightly larger diameter screw in the same hole as before. Looking at the spacing, this should not make them merge together because you are only increasing the size of the hole by fractions of a millimetre.

If you are driving the screw into the same hole, you should get away with using a screwdriver, but a drill would definitely work. If you are using a new hole, you would need a drill.

To put it simply, use a sheet metal screw with a thread that is slightly larger in diameter than the hole and drive it in with a screwdriver or drill. The main thing is that you need a wider screw so that it bites.

Let me know if you need further assistance.

Jacob

[R4addZ]

Hi @Eloise- 

First I need to ask some silly questions.....

Is the door fully closed in the second set of pictures as things do not seem to be sitting right. The "Beak" is so far extended that the two notches above and below do not have the door "Pips" (for want of the correct term) sitting in them. This could compromise the security of the door.

Is this new handle the same as the previous one as it should pretty much line up with the old setup?

Is it possible that the position you tried screwing the new strike onto the frame has created Burrs on the inside of the frame that are now preventing the door from closing fully and this is why the fixing holes do not line up with the old plate? You can check with a tape measure or ruler how deep the frame is and put a pencil mark on the door and slide it shut to see if it is sliding all the way in. If not, clean the burrs off the frame and try again.

[Nailbag]

Hi @Eloise- 

The diagram below may be more helpful on what I was trying to explain.

And as @JacobZ pointed out the pilot hole for the screw needs to be minimal so the screw bites hard. You will need to use a Phillips screw driver and not a drill/driver or impact driver to avoid stripping the thread. It will be tough to turn the screw. If not possible, then go half a mm size up in pilot hole. If you strip the thread you will need to go a size up in screw.

This process will work as I have repaired many sliding door handles in the same scenario.

Nailbag

 

 

[Noyade]

"The holes didn’t seem massively over sized but they weren’t biting into anything either"

Just another hardware thought @Eloise- if the screws aren't binding and the aluminium is becoming Swiss cheese - maybe a small bolt with a thin square nut may suffice? Trim the bolt remainder as above.

Good luck.