Replace a Lock Block on a door - dutchman style!
If you need to replace the lock block on an interior door, perhaps because you need to install a different style of door handle, here's how to do a dutchman repair.
Dutchman is a woodworking term used to repair or apply a patch if you need to fill or cover a repair or gap in wood or wood products, or in this case the lock block on a hollow-core interior door.
Replacing doors simply because you want to change the door handle or lock can be expensive. It works out far more cost effective to use the dutchman patching method to replace the lock block in a door, and this will allow you to fit new handles and locks.
1. Remove the old handles and lock components.
2. Use a flathead screwdriver or small wood chisel to remove material from the original lock installation.
3. Cut out a template using scrap 16mm SupaWood.
4. Clamp the template firmly to the door and workbench.
5. Using a cutting guide in a router, Inset cutting bit and set for correct cutting depth. This will depend on the thickness of the timber you will be using to patch the door, but should not exceed 12mm in thickness. This will leave behind a lip for gluing the patch in position.
GOOD TO KNOW: The cutting guide will follow the line of the template to remove material from the door.
6. Use your router to remove material from the door to allow for fitting the wood patch.
7. Cut the patch to fit the opening and test for a snug fitting.
8. Apply a liberal amount of wood glue to the lip.
9. Place wood patch in cut out and make sure it is firmly bedded.
10. Use a plane and sander to remove excess material that sits proud of the door surface. You want a nice smooth, seamless finish that will be invisible once painted.