I have a customer that has asked me to replace the old style with new style handsets.
I’m trying to figure out what the best way of going about it is. I don’t know if I should create a jig and Lee mortise the existing hole to accommodate a specific size piece of wood that I can glue inside.
Any ideas or suggestions I haven’t done it before although I know what needs to be done and I need to figure out how much time I would need to invest per door in order to input an estimate.
If the mortises are not consistent, I think I would go with the jig and cut them so they would accept a consistent block of wood. Bit I would say that depends on how many you have. If it is just a couple, fit them individually, if it is a lot go with the jig.
I thinking they were all hand chiseled so if I plunge routed a consistent hole then I could plug it with an appropriate piece.
I could rip the thickness and round over the edges to match the plunge radius.
I’ve only ever did one door so I just did a hand fit. Made the filler piece a snug fit, glued it up and tapped it into place. The one I did appeared to be drilled with a series of holes so I had sone chisel work to do to clean that up. It may go alot faster with the router