Door Hole Plug

thingiverse

This is a custom-made plug designed to fill a deadbolt space temporarily in a door. My initial version featured male threads running all the way down its length, but it had one major flaw - the aggressive threads made it difficult to remove the support pieces I had added. To overcome this issue, I created a new version 2 with an undercut, which has proven to be a much better solution. I strongly recommend taking two steps to improve your plug design: first, push out the support gaps by at least .5 mm; second, print the inside threads of the plug instead of relying on external threads (this approach may take more time according to your slicer). If you're interested in modifying this design further, I've included the SolidWorks files for your reference. This plug fits seamlessly into a standard US hole on a 1.75" thick door and draws tight with ease. If you're concerned about it spinning out of control, I suggest using a plug with teeth on the outside that will bite as you tighten down - this feature proved unnecessary in my case but may be essential for working with heavily painted older wood doors.