How to replace privacy handles on old 35mm doors?

[David14]

I purchased a Privacy door handle set to start  replacing all my door handles. The box clearly stated it would fit 35-45mm doors. Mine is 35mm.

The spindle is for a 45mm thick door and there’s no mention on the instructions how to reduce the spindle to fit a 35mm door. There’s no adjustment available on the handles. Been back to Bunnings twice and the only option the staff can come up with is cut the metal spindle back to reduce the size ? Surely this would have been mentioned on the instructions !? Anyone else had this problem?

[JacobZ]

Hi @David14,

Welcome to the Bunnings Workshop community, it is fantastic to have you with us.

Having installed numerous door handles over the years, I can tell you that every door handle I've encountered that can be installed in doors of varying thicknesses comes with a spindle designed for the thicker door, which you'd need to cut down for the thinner door. They also come with notched bolts that need to be cut down. Unfortunately, I've never come across a better solution, and I've never seen the instructions on the door handles mention it.

The simplest solution is to grab a hacksaw and a clamp, then clamp it to a surface so it doesn't move and cut 10mm off the length of the spindle. If there are any burrs left after cutting, you can use a file to tidy up the spindle.

For the bolts, use a pair of end cut pliers on the right notch for the door thickness. The pliers are better for this purpose as they won't have any effect on the thread, whereas a hacksaw or angle grinder can.

Unfortunately, it is the frustrating reality of door handles.

Let me know if you have any further questions.

Jacob

[David14]

Thanks for the quick response Jacob, that’s very helpful. Not what I really wanted to hear but it confirms my ‘fears’ that those simple little jobs end up being a little more involved.

Again, thanks.

[Nailbag]

Hi @David14 

I have replaced countless door handles over the years and have to say I can't recall ever needing to cut a spindle down, only the securing screws. If the packet states 35-45 and it doesn't then I would be taking the set back or aa @JacobZ mentioned cut the spindle down with either a hacksaw or angle grinder.

Nailbag