How to repair a hole in an internal door

MitchellMc

Steps

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Step 1

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Remove the door from the frame.

Use a screwdriver to remove the screws from the hinges. Ensure you have someone supporting the door to prevent it from falling once the screws are removed.

Carefully carry the door and place on a solid work surface. A pair of saw horses or a sturdy table works well. Lay the door flat to provide a stable platform for the repair.

1.1 Damage to door.png 1.2 Closer shot of damage.png 1.3 Removing hinge screws.png

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Step 2

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Expose the door’s structure.

Before you can repair the hole, you need to prepare the damaged area. Carefully pull away any broken or loose pieces of the outer door skin to expose the internal structure of the door. This will often reveal a cardboard honeycomb layer inside. Ensure the exposed area is clean and free from debris to allow for better adhesion of repair materials.

2.1 Removing damaged outer skin.png 2.2 Outer skin removed.png 2.3 Edges cleaned up.png

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Step 3

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Insert support pieces.

To provide a solid backing for the repair, you'll need to insert thin pieces of timber behind the outer skin of the door. Wooden paint stirrers are perfect for this. Measure and mark the paint stirrers so that they are slightly longer than the width of the hole. Clamp the stirrers to a solid surface and use your saw to cut them to the correct length.

Add Liquid Nails or a similar adhesive to the ends of the paint stirrers. Slide the stirrers into the hole behind the outer skin of the door, positioning them horizontally so they provide support.

Once installed, add another bead of glue around the edge of the hole.

Ensure the Liquid Nails is fully dry before proceeding.

3.2 Marking timber backing.png 3.3 Cutting backing pieces.png 3.4 Backing pieces cut.png 3.5 Glue applied to backing pieces.png 3.6 Inserting backing pieces.png 3.7 First backing piece inserted.png 3.8 All backing pieces inserted.png 3.9 Adding additonal glue.png 3.10 Additional glue added.png

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Step 4

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Fill the hole.

Fill the hole using Builder’s Bog - a two-part filler. Combine a small amount of red catalyst with the larger white filler part. Mix with your scraper thoroughly until you achieve a consistent pink colour.

Use your scraper to apply the Builder’s Bog into the hole. Start by working around the edges and then fill the central area.

Once the filler is dry, check for any depressions. If needed, mix a second batch and apply another coat to create a smooth, even surface.

4.1 Measuring out Builders Bog.png 4.2 Mixing Builders Bog.png 4.3 Applying Builders Bog.png 4.4 Adding Builders Bog to edges.png 4.5 Filling middle section.png 4.6 Builders Bog applied.png

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Step 5

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Sand and paint the door.

Once the Builder’s Bog is completely dry, sand it back flush with the surface of the door using 80-grit sandpaper. Then use 120-grit sandpaper for a smoother finish.

Lightly sand the rest of the door with 180-grit sandpaper to ensure a consistent surface for painting. Wipe the door to remove any dust created by the sanding process before proceeding.

Use a roller to apply your undercoat to the entire door. Allow it to dry completely. Once the undercoat is dry, apply two topcoats of enamel door paint, allowing each coat to dry thoroughly between applications.

Return the door to the frame and fasten the hinges securely to complete the project.

5.1 Sanding bog with 80-grit sandpaper.png 5.2 Sanding bog with 120-grit sandpaper.png 5.3 Bog sanded.png 5.4 Undercoating door.png 5.5 Painting door.png 5.6 Finished repair.png