Enlarging door latch hole

real_aurgathor

I want to install a door handle, but the door latch seems to be a bit too tight. Normally, I should be able to push it by hand, but not in this case, I tried to force in with the help of a deep socket – but even that way it was showing more than enough resistance that I decided to stop because I was afraid that I will crack the door.

What would be the best way to slightly enlarge that hole?

egeezer

Absent a Dremel tool with a cylindrical sanding bit, I’d use a fine half round file to carefully dress the hole. Be careful to keep the opening circular.

Rubbing the finished surface with beeswax or paraffin can make it easier to fit doweling, or in your case, the bolt assembly.

RayGeode

To try to budge the latch, Any combination of WD 40 , Hair drier, Light taps with a mini hammer
And / or Large open jaw plier to try to rotate.

To enlarge the hole: foam rubber wrapped with light sand paper can be rolled up to a cylindrical shape to fill the latch hole. Rotate it until size desired. Tighter fit / heavier grit sandpaper, the more the more abrasion.

real_aurgathor

RayGeode To try to budge the latch,

Given the resistance I faced, I concluded that there is at least a ⅔ chance of damaging the door if I try the brute force approach. Furthermore, even if the door survives that, the latch the would be *exceedingly* difficult to remove in the future.

RayGeode To enlarge the hole: foam rubber wrapped with light sand paper can be rolled up to a cylindrical shape to fill the latch hole. Rotate it until size desired.

That’s a good basic idea, though I need something that is automatically centered and preferably can be driven by an electric drill – perhaps a deep socket that’s a bit smaller than the hole.

RayGeode

real_aurgathor Given the resistance I faced, I concluded that there is at least a ⅔ chance of damaging the door if I try the brute force approach.

Small steps at a time, like tapping the lid of a jar of pickles.

real_aurgathor I need something that is automatically centered and …..

Centering is automatic with this up to a certain point. Depends on need for precision. Of course, this won’t work for more than a small fraction oversize.

Cheers!

real_aurgathor

It wasn’t exactly what I was looking for, but HF had a drum sanding kit (2″, 1″ ¾″, ½″) for $6.99, and I’ve had 30% off coupon, so I decided to buy that instead of creating my own, custom sander using a deep socket.

It took quite a a bit of sanding with the coarsest (80) sandpaper included, but eventually it went in fine with only bare hands and a deep socket. Still a much tighter than normal fit, and it’s not completely in, but I got tired of sanding, and I won’t lose much sleep over about 0.5 - 1.0 mm since there’s more than enough clearance.