Cutting a small notch in uPVC door

Wheety · 17-12-2021 12:48AM #1

I need to replace the handles on our back door. I bought a set in Screwfix and everything seems to line up apart from at the top of the baseplate the screwholes have a protruding part. This is cone shaped and it won't fit in the existing hole on the door. I need to make a little notch/semi circle at the top of the existing hole so it will fit. Only need a few mm.

I was thinking a small round file/rasp, which I would need to pick up in B&Q. I have a small hacksaw, a drill, a Dremel (but don't know if any of the attachments would do the job) and a jigsaw. I also have a larger file but don't think it would suit.

Any idea what would be the best way of tackling this?

Would an appropriate size drill bit be able to "saw" through it sideways?

the_pen_turner · 17-12-2021 01:08AM

are you moving the hole up or down or just countersinking it a bit . i dont think you can move the holes. the screws go through the lock i think . if its plastic i would get one of those cone shaped grinding cutters you see in co ops that go in a drill and widen the hole

SFASTER 1/4 Shank Cone Shaped Corundum Grinding Heads 10pcs/Set Abrasive Mounted Stone Grinding Wheel Head Rotary Tools Deburring Polishing Rotary Kit Abrasive Stone Points : Amazon.co.uk: Business, Industry & Science

Wheety · 17-12-2021 01:58AM

I want to make the holes in the face of door frame itself slightly bigger so the new handles will fit. Everything else lines up as the same as the old handles.

It's just the protrusions on the back of the screw holes on the new handles preventing them from fitting. Only the top holes too

the_pen_turner · 17-12-2021 09:07AM

I would use a larger drill bit then

garv123 · 17-12-2021 05:21PM

wriggle the drill bit up/down.

Dr_Colossus · 17-12-2021 11:08PM

Set of needle files will do that job nicely OP, nice and tidy. Useful to have for again

https://www.mcquillantools.ie/draper-83982-140mm-soft-grip-needle-file-set-6-piece/

Wheety · 18-12-2021 11:26PM

I ended up using my Dremel with something like this (from a Lidl accessory kit) Diamond Wheel Point 2,4 mm Carving/Engraving/Routing | Dremel

Just shaved a small notch and fitted the handles today.

Only had a look at doing it today and I had made it a bigger job in my head really. Surprised how soft the uPVC material was.

Cutting a small notch in uPVC door

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