Extensible door hole plug

Got an exterior door for my office and needed something to fill the predrilled deadbolt holes.

Wanted something that was a more secure than the pop-in designs I was seeing and also a bit more decorative.

Tried some different variations and this is what I came up with in Tinkercad.

General features:

• Stepped back to align with any hole that's at least 53mm wide
  • I had issues with other plug designs that relied of friction fit being either too loose or too snug between different doors
• Different connecting rod lengths could be used for different door thicknesses
  • Included rod works for exterior doors that are ~44mm thick
    • Has enough depth in the recesses & length in the threads to allow for a little more or less than that
• No need for tools, tightens pretty securely by hand
  • May need something for extra grip to remove
• Front face can have a design cut out
  • Models are included both with the design I used and blank if you want to create your own cutout (easy to do by importing an SVG into Tinkercad)
  • Could be flipped over and printed with supports if you wanted something 3-dimensional

Note: if you need security (like an exterior door for a house), you're probably better off with a metal plate

Print settings:

• Faces
  • Print 2 of these
  • Orient face-down so the design faces the build plate
    • (model should default to this)
  • No supports needed
  • 3 walls & 15% infill seemed sufficiently strong
• Connecting rod
  • Print 1 of these
  • Orient standing on end
    • (model should default to this)
  • No supports needed
  • Print with 100% infill (I'd tried lower but had issues with the threaded end breaking off)

Uses ~40g of filament

Have included some of the different component parts for easier remixing.

(AI Generated tag because the relief on the face was based on an AI-generated image that I converted to an SVG and tweaked in Inkscape)