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Shaft Extension for Door Latch

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  • Shaft Extension for Door Latch

    My customer made a custom door, which was considerably thicker than a standard door. This meant that standard door knob hardware would be too short to reach through the door. Door knob extension kits are available, but these were also too short. To solve the problem my customer purchased a second door knob assembly so that he could scavenge the two shaft parts that were required. The task was to weld an extension to the outer piece that looked like half of a pipe. The inner piece appeared to be made of pot metal and I was reluctant to attempt to weld it. I know that Muggy Weld makes a Super Alloy 1 product that can weld pot metal, but a kit costs $105. My customer and I decided to machine a sleeve to extend the shaft, which would be glued on using Loctite 680. The first picture shows the drawing and the parts that my customer provided.
    1. Drawing and parts
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    I was concerned that the sleeve would interfere with the numbs on the ID of the shaft so I ground them off.
    2. Grinding off nubs
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    I like to remove the plating before I machine plated metal to avoid smearing the plating on the area to be welded, because the plating will cause porosity in the welds.
    3. Etch off plating in HCL
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    4. Plating removed
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    The first machining task was to remove the radius on the end of the shaft in preparation for welding.
    5. Squaring off one end
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    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Colchester 15" Lathe
    16" DoAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

  • #2
    Next, I trimmed the end of the outer extension shaft.
    6. Trimming off the other end
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    Below are the machining tasks that were performed on the inner shaft.
    7. Facing end
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    8. Center drilling
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    9. Turning OD
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    10. Nice coil chip
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    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Colchester 15" Lathe
    16" DoAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

    Comment


    • #3
      Here are some additional tasks for the inner shaft.
      11. Parting shaft
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      12. Drilling shaft
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      13. Reaming shaft
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      Next, I sanded off the mill scale in preparation for welding.

      14. Grinding off mill scale
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      Now I was finally ready for welding.

      15. Setup for welding
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      Smith Oxyacetylene Torch
      Miller Dynasty 200DX
      Lincoln SP-250 MIG Welder
      Lincoln LE 31 MP
      Lincoln 210 MP
      Clausing/Colchester 15" Lathe
      16" DoAll Saw
      15" Drill Press
      7" x 9" Swivel Head Horizontal Band Saw
      20 Ton Arbor Press
      Bridgeport

      Comment


      • #4
        Now the welding steps:
        16. Ready to tack weld corner
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        17. Welded out
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        18. Close up of weld
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        I didn’t want to penetrate on the inside, because it would interfere with the inner shaft.

        19. Inside of weld
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ID:	612049 The next step was assembling the inner shaft with 680 Loctite.

        20. Sleeve Loctited
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ID:	612050
        Smith Oxyacetylene Torch
        Miller Dynasty 200DX
        Lincoln SP-250 MIG Welder
        Lincoln LE 31 MP
        Lincoln 210 MP
        Clausing/Colchester 15" Lathe
        16" DoAll Saw
        15" Drill Press
        7" x 9" Swivel Head Horizontal Band Saw
        20 Ton Arbor Press
        Bridgeport

        Comment


        • #5
          Here is the painted shaft.
          21. All done and painted
          Click image for larger version

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          And here is the whole latch assembled.
          22. All done and painted
          Click image for larger version

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          -Don
          Smith Oxyacetylene Torch
          Miller Dynasty 200DX
          Lincoln SP-250 MIG Welder
          Lincoln LE 31 MP
          Lincoln 210 MP
          Clausing/Colchester 15" Lathe
          16" DoAll Saw
          15" Drill Press
          7" x 9" Swivel Head Horizontal Band Saw
          20 Ton Arbor Press
          Bridgeport

          Comment


          • #6
            Wow.....very nice..

            Comment


            • #7
              Very nice , you have a a lot more patience then I have

              Comment


              • #8
                Very tedious craftsmanship. Thank's for posting.

                Comment


                • #9
                  Beautiful reults, and really great pictures, as usual! You do nice work, Don.

                  Comment


                  • #10
                    It is now the most expensive door knob on the planet! And one of kind!!

                    Comment


                    • #11
                      Originally posted by ryanjones2150 View Post
                      It is now the most expensive door knob on the planet! And one of kind!!
                      Here is what my friend and customer had to say:

                      “Thanks Don! I showed the entire process to Wendy and Carolyn just now during dinner. Our shed door latch is famous!
                      One question, why did your customer make such a thick door? Answer: because he could!”

                      -Don
                      Smith Oxyacetylene Torch
                      Miller Dynasty 200DX
                      Lincoln SP-250 MIG Welder
                      Lincoln LE 31 MP
                      Lincoln 210 MP
                      Clausing/Colchester 15" Lathe
                      16" DoAll Saw
                      15" Drill Press
                      7" x 9" Swivel Head Horizontal Band Saw
                      20 Ton Arbor Press
                      Bridgeport

                      Comment


                      • #12
                        Welding on one side, how did you keep the outer shaft from curling up?

                        Comment


                        • #13
                          Originally posted by Chris401 View Post
                          Welding on one side, how did you keep the outer shaft from curling up?
                          On picture #16, you can see the aluminum bar that I clamped it to, which helped keep it straight. Also I tack welded both ends before I welded it out.

                          -Don
                          Smith Oxyacetylene Torch
                          Miller Dynasty 200DX
                          Lincoln SP-250 MIG Welder
                          Lincoln LE 31 MP
                          Lincoln 210 MP
                          Clausing/Colchester 15" Lathe
                          16" DoAll Saw
                          15" Drill Press
                          7" x 9" Swivel Head Horizontal Band Saw
                          20 Ton Arbor Press
                          Bridgeport

                          Comment


                          • #14
                            I see it now.

                            Comment


                            • #15
                              What tools did you need to create this shaft extension? I want to build a shaft extension for my old door with deep-set and hard-to-reach lock. Thus, I hope I will be able to easily reach and manipulate the latch mechanisms. With the help of emergency locksmiths se20 I will have quick access to a locked door if needed- lockout or other types of security issues.
                              Last edited by MindFlashback; 01-03-2023, 08:11 AM.

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