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Yeah, know what you mean. It's best to fit them on the cross section where depth is not an issue but if you don't want to move the latch plate on the frame, just measure what you have to play with and get the longest one you can without imposing on the panels. Just remember, you need enough...

Check out cromapol or similar products. Much easier to apply than GRP. Doesn't set solid like GRP tho so that may or may not be what your after.

If they are knobs and not handles, I would get the longest you can get. That way, when the door is closed, the knobs are away from the frame making them easier to operate. I retro fitted some knobs a while ago onto short latches and you could hardly fit your hand round them because they were too...

Fire??

CT1 power grab n bond. Best I've used! Depends what it's for tho.

Try a stain blocker. Loads of em on the market. I use a solvent spray by zinseer, dries in 10 mins, leaves a matt finish ready for going over with emulsion.