DEADBOLT INSTALLATION

Here's what I accomplished this morning:

First hole drilled after much contemplation...



Hole saw centered on the pilot hole cut from the inside but it missed the vertical edge trim on the outside anyway:






I reattached the inside skin with clecos and clamps then lined up the hole saw and cut:


I cut the outside trim ring to fit over the vertical edge trim. A diamond burr in the die grinder was used:





This was the toughest hole to locate well:




Temporarily fit but still needing caulk. I also want to fill the wall with stiff foam to stiffen the wall to avoid distortion caused by compression of the inner and outer walls:



To transfer the exact center of the bolt to the door I glued a pencil eraser on the end and covered it with magic marker before closing the door and pushing the bolt out.





I drilled out the center and opened up the hole with the the die grinder.


I filed the bolt as little as possible and it turns out it's exactly the same width as the the door latches bolt. Also, the deadbolt lines up exactly with the door latch hole location on the door jam. I will certainly reinforce the door with something to back up the hole where the deadbolt goes.


By the way here are the tools I used to accomplish this job. Difficulty level: FAIR