doorsinterior
I screwed up when ordering new door slabs. Measured everything except the thickness, and, of course, I wasn't lucky.
Anyway, the door is pre-mortised, and it won't close because it is too thick. I am trying to figure out the best way to proceed given the fact that it is pre-mortised and with the holes for lock-sets.
Can I simply trim the door stop with a circular saw or a router? If not, what other options do I have?
Thank you.
As DA01 said - cut one inch off of either side of the door jamb.
You're going to have to drill a larger hole for the new handles, which should completely encompass the old hole.
Head on down to your local hardware store (or cruse the internet), and look for a door handle installation jig like this Irwin® Door Lock Installation Kit
Example only, these jigs are available from many different manufacturers
It comes with the proper size hole saws to set up a door for modern locksets, and makes alignment of the holes quick and easy. Simply attach the jig where you want it, and drill the holes with the supplied hole saws.
Best Answer
You can't (practically speaking) make your slabs thinner. It would be a monumental undertaking considering the nature of hollow-core doors and symmetrical mortising. You can either move the stops or get new slabs and start over.
To move the stops, slice the paint with a utility knife, then work a steel putty knife behind the stop to loosen it. Gently pry the stop loose. Sand, fill, and paint the jambs.
Determine whether the stops are salvageable with sanding and repainting. Reinstall using trim nails and filler, and apply a final coat of paint.