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How to fix a too big door knob hole without purchasing a new door knob set?

I am trying to fix this door knob. I think I found a solution on youtube but I cannot find what they used in the video so I am attempting to post this here and maybe there is another way to fix this. I already try to tighten the screws but the problem is that the hole is too big. I do not want to change the door and I already have a lot of door knob set so I do not want to buy a new door knob set (a bigger one).

Thank you

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Repairing

Doors and Windows

Comments

EricL

Hello @Vai

Welcome to the Bunnings Workshop community. It's fantastic to have you join us, and thank you for sharing your question about fixing your door knob.

The doorknob you purchased has the capacity to be installed on a door that is 55mm thick. If you have a 40mm door, I suggest using 897 x 600mm 7mm Plywood Pine BC Grade as a cover plate for the hole in your door. I recommend cutting two squares at 150mm x 150mm and putting one on each side. I propose using Selleys 100g Liquid Nails Construction Adhesive along with Zenith 8G x 35mm Gold Passivated Countersunk Rib Head Chipboard Screw.

Once the holes are covered, I suggest cutting new installation holes for your door knob. Please make sure to use the template provided in the packaging in your doorknob set. I've placed some images below to give you an idea of how to repair your door.

If you need further assistance, please let us know.

Eric

JDE

I haven't done this before but you can buy commercially made spacer rings to reduce hole size ( try fleabay) or bunnings sell a lock reinforcer (Adoored 60mm 1 hole backset door reinforcer) it might be worth looking at. Not sure if will match your offset but at $18 worth a look. JDE

Walter

@Vai

Here's a work in progress. I 3D printed out a "washer". 50% infill means it is strong enough. I just had to get the dimensions correct, but now that I have that, I can reproduce that as often as I want.

I'm changing the colour of the filament to more closely match the door knob, but before I finish, I'm repainting the door 😀

michellem200

https://www.workshop.bunnings.com.au/discussion/comment/22627#Comment_22627

But won’t the wood coverings protrude out and not be flush with the door itself?

EricL

https://www.workshop.bunnings.com.au/discussion/comment/85911#Comment_85911

Hello @michellem200

Welcome to the Bunnings Workshop community. It's sensational to have you join us.

You are correct, the patch has to be adjusted to make way for the door frames timber moulding. In this manner the door will still close flush to the assembly. The patch will still technically work it just needs to move away from the edge of the door.

Thanks for spotting that.

Eric

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