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l would probably go with your plan of packing out the overlap on the door side, in case you ever want to revert in the future it would be a lot less hassle. Hacking into the door frame is rather ... permanent.
Lurking ...
Have you got some pictures of the lock or make and model for the lock that you are wanting to replace that mortice with?
@Fbags1 Maybe I’m misunderstanding your drawings, but it looks like you believe the handle has to point to the left? I’d be extremely surprised if it can’t be easily reconfigured to have the handle point to the right instead to suit you door. Would that solve you problem?
EDIT: The photo looks like a Yale SL7100. You can definitely change it from left to right handed as per installation guide.
Fbags1: No it's the actual latch mechanism in the door is too long so the number plate bit needs to shift over but the bit it needs to sit on there's a recess. If we use the latches mechanism in the older style one the combo plate can sit on the flat part but it's too large so we are unable to close the door hence having to possibly cut into the frame which im not keen on.
Right, I see. If those are the only options I’d pack the door as yourself and others have suggested. With a little care this could be done quite neatly. You have a much bigger chance of messing up by cutting into the frame (and, like you said, it would look bad).
As another thought, have you spoken with a locksmith? Perhaps they could source a latch shorter than the combo lock one, but longer than the old one?
Yes, as above post, that is correct - if you figure out your backset measurement, then possibly to find an alternative lock or also mentioned above chat to a locksmith to help the search.
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