How to Flush-Mount a Mortise into an Aluminium Door (AUSLOCK)
If your aluminium door cut-out is not perfectly flat or square, you may need to flush-mount the mortise so the lock sits correctly and the handle works smoothly.
What you’ll need
- Marker/pencil
- Tape measure
- Chisel or router (depending on the door type)
- File/sanding tool for clean edges
- Safety glasses
Step-by-step (general guide)
- Remove the existing hardware and insert the mortise to test fit.
- Mark the outline of the mortise faceplate on the door edge.
- Create a shallow recess so the faceplate sits flush with the door edge (do not over-cut).
- Test fit repeatedly until the mortise sits flush and straight.
- Install screws and confirm the latch retracts freely.
- Reinstall the AUSLOCK handles and test locking/unlocking.
Common mistakes to avoid
- Cutting too deep (causes wobble / misalignment)
- Not aligning the mortise vertically (handle binds)
- Over-tightening screws (can distort alignment)
Need help? Use our compatibility check and attach door photos + mortise photos.