Howdy,

"How hard can it be?" I figured. Unfortunately I came to learn the
hard way that the bore sizes on my/8" thick interior doors are weird
in my 1970-built home:

1.75" diameter handle bore, (center of which is a 2 3/8" setback)
7/8" on the bolt bore. Door is 1 3/8" thick.

Anyone know of any inexpensive replacement handles designed to drop
into these without having to drill out the existing doors?

Modern door handle sets available everywhere seemingly have a template
for a 2 1/8" bore or more--and everyone considers them standard.
While some of these can handle the little 7/8" size bolt bore I have,
some require a full 1". The problem I have is that when inserting the
bolt, it can't be inserted all teh way because the relatively small
handle bore isn't big enough to allow the bolt to come all the way in.
The medial of the handle bore is 3.25" from the door edge, and most
bolts need 3.5" of depth to fit, even with setback adjusted for the
minimum.

I wouldn't be so opposed to drilling if I knew of a tool that could
easily enlarge and center an existing bore (seeing as a standard hole
saw has nothing to center on).

Thoughts, aside from replacing all the doors? :-) Is there a handy
hole saw designed for the duty I need here? Or would doing this
require putting something temporarily in the hole to center a
standard bit?

--
Todd H.
http://www.toddh.net/