How to machine for a lock on a Duramax Plus Composite Door [Video]
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:
- Mark Mortice: Mark cut out for mortice on door edge.
- 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.
- 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.
- Drill mortice: Drill mortice into LVL using auger drill bit.
- Clean mortice hole: Clean out remaining debris with a sharp chisel.
- Check to ensure lock fits into mortice hole: Insert lock into mortice hole. If it doesn’t fit, remove more materiel from the hole.
- Mark outline of the face plate.
- Cut outline of the face plate: Use the multi-tool to do this.
- Chisel out recess: Remove 1.5mm-2mm of the PVC with a chisel.
- Mark centres of face holes: Do this by placing lock on the door face, lined up to the edge of the door.
- Machine for face holes: Use diamond hole saw to machine the face holes.
- Fit lock.