I am trying to reinforce a custom door I am building. Because it's made only of two layers of MDF, it is not as rigid as I want it to be and shows signs of bowing. Since it's going to be a soundproof door, any curvature in the door will be detrimental to a tight seal around the stop.
The only low-profile solution to reinforcing the door that I have found is a 1/8"x1 1/2"x6' length of steel that I found at Menard's. It is very ridgid and would be perfect for attaching along the inside edge of my door which is also 1 1/2" thick. The problem is that I need to drill a 1"-diameter hole through it for the latch assembly, but I have no idea how I am going to do that with the cordless power drills that I have.
Best Answer
Using a holesaw in steel that's more than about 1/16" thick can be frustrating. The bits wear out fast, and it really likes to bind. I've had better luck using a step drill bit, like this one from Harbor Freight.