On a job that's on 2000 code getting modded. every door has lunar key holes. different style locks spec'd so need to drill new holes and plug old ones. customer doesn't want the normal filler plug we use. they'd like to fill the hole, but of course don't want to remove the doors to get welded or reskinned. anyone have any ideas? i was thinking of enlarging the hole on the hoistway side so I could use a piece of metal and 2 part epoxy it. this ways the building has a backer they can apply bondo or sort of filler to make the hole flat.
There’s a guy in my area that will fix doors in place. Refinish, fill holes, stainless, bronze, whatever. He’s really good. Definitely cost more than a plug though.