Parkwood Duramax Plus composite doors contain a fibreglass pultrusion inside the lock stile for enduring stability and strength. The pultrusion makes conventional morticing techniques difficult.

Parkwood recommends getting Duramax Plus doors pre-machined for locks, if that is not possible please watch this video or follow the instructions below.

Important tools to use:

1. Mark Mortice: Mark cut out for mortice on door edge.
2. Cut through PVC layer: Using a multi-tool, cut the rectangular mortice through the PVC up to the pultrusion. Remove this in one piece using a chisel.
3. Drill through pultrusion: Use diamond hole saw to cut through pultrusion wall. If mortice is more than 65mm deep then drill through the back wall as well.
4. Drill mortice: Drill mortice into LVL using auger drill bit.
5. Clean mortice hole: Clean out remaining debris with a sharp chisel.
6. Check to ensure lock fits into mortice hole: Insert lock into mortice hole. If it doesn’t fit, remove more materiel from the hole.
7. Mark outline of the face plate.
8. Cut outline of the face plate: Use the multi-tool to do this.
9. Chisel out recess: Remove 1.5mm-2mm of the PVC with a chisel.
10. Mark centres of face holes: Do this by placing lock on the door face, lined up to the edge of the door.
11. Machine for face holes: Use diamond hole saw to machine the face holes.
12. Fit lock.

Learn more about Duramax Plus