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How to repair large hole in door?

Jay_11
Growing in Experience

How to repair large hole in door?

Hi all,

I am going to head to bunnings soon but need help with advice on the cheapest and easiest way to sort out a large hole in my bedroom door. I have a few ideas from reading some tips on the net but rather have someone on here with expertise to advise and recommend what products to buy and use to fix this. I've attached two photos of both sides of the bedroom door.

 

Any help and advice would be much appreciated. Thanks

 

Community manager's note: Check out How to repair a hole in an internal door for expert advice.

 

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Jay_11
Growing in Experience

Re: Large hole in door

Makes sense that I couldn't find them on the Bunnings online store.

Thanks anyway for your help, Mitchell

MitchellMc
Bunnings Team Member
Bunnings Team Member

Re: Large hole in door

How stuck are the screws, @Jay_11? Can you take a picture of them for me? 

 

Do you have any WD40 or oil that you could spray on them to try and help get them out? Have they been painted over and need the paint scraped back to release them? Or are the cutouts for the screwdriver bit worn away completely?

 

Please keep us updated on whether you will try to repair the door or continue trying to install the new one. I'm here to assist every step of the way. I'd you'd like to talk through trying to repair the door, we can do that.

 

Mitchell

 

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Jay_11
Growing in Experience

Re: Large hole in door

Thanks, Mitchell.

I think the grooves / cutouts in few of the screws are really warn away. I was able to losen most of the screws with a screwdriver but two screws just would not grab at all. Tried different sized screwdriver heads too but they still don't budge.

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I've hung the old door back up for the time being. Kind of torn between to still give the newer door a try or leave it altogether due to the hinges, possible width issue and door stopper change over.

I would've preferred to buy new hinges that are the same as the old door and give it a go. But like you said they do look proprietary made.

Perhaps trying to repair the hole would be best at this stage. 

 

Does Bunnings sell thin scrap wood so I can try fill it in the hole? I was thinking to buy some liquid nails to let it set then use bog to start filling it in. Sandpaper wise, do you recommend 100 grit?

MitchellMc
Bunnings Team Member
Bunnings Team Member

Re: Large hole in door

We have 3mm MDF which would be good the cut thin strips from and glue behind the front skin of the door @Jay_11. If you visit a store you might also find some thin strips of scrap timber that would work. Pro-tip: check the racks of 90 x 45mm structural timber. It comes separated by these thin strips of timber that would be perfect. The team in-store will let you take them for free.

 

For the screws that have stripped heads, try putting a couple of layers of painter's tape over your screwdriver tip. Sometimes this is enough to get them to grip.

 

80-120grit sandpaper would be good for cutting the bog back that is proud of the front face of the door. You'll then need a higher grit, like 180-240, to smooth it off.

 

Mitchell

 

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Jay_11
Growing in Experience

Re: Large hole in door

That's awesome. I'll try going to Bunnings tomorrow. Would the liquid nails set fast?

 

As for the screws, I'll need to buy some painters tape to try that tip! 

 

In regards to the bog, what would you recommend for the job? I think maybe 1 litre would hopefully cover front and back of the door. Any particular primer that Bunnings has for this patch job?

I think I have a wide spatula laying around.

 

EricL
Bunnings Team Member
Bunnings Team Member

Re: Large hole in door

Hello @Jay_11 

 

If you're having a hard time removing the screws because the heads have been rounded off, I suggest using the Frost 5 Piece Extractor Screw Set, this will allow you to extract the screw out with relative ease. Please note that it is important that you drill a hole in the middle of the screw first before you use the extractor. Do not use the extractor itself as a starter drill bit.

 

My only tip with using Builders Bog is to make sure not to use too much activator. Excessive use of the activator will harden the bog immediately giving you no time to spread and flatten it out.  

 

Any standard primer should work on your door, just keep in mind that the surface of the door must be sanded down before applying the primer. Remember to use a compatible topcoat with the primer.

 

Here is a link to our best advice: How do you remove damaged screws?

 

Here are some handy step-by-step guides:

 

 

If you have any other questions we can help with, please let us know.

 

Eric

 

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Jay_11
Growing in Experience

Re: Large hole in door

Thanks, Eric. Good to have those additional tips in removing stubborn screws.

In terms of the primer, i was considering in purchasing the following:

https://www.bunnings.com.au/british-paints-white-4-in-1-prep-water-based-primer-sealer-undercoat-100...

EricL
Bunnings Team Member
Bunnings Team Member

Re: Large hole in door

Hi @Jay_11 

 

Using British Paints White 4 In 1 Prep Water Based Primer Sealer Undercoat - 1L should work just fine. Please keep in mind that you might need to do more than two coats if the tone of the old paint is still visible. I suggest observing the door carefully when it's totally dry after. You should be able to tell if it needs one more coating by then.

 

If you need further assistance, please let us know.

 

Eric

 

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Jay_11
Growing in Experience

Re: Large hole in door

Thanks, Eric. Should I just stick with a normal primer or go with the 4 in 1?

The colour of the door is Beige. I may have to bring a broken piece into Bunnings and ask for assistance at the Paint section to get a close match. I'm guessing water based paint.

EricL
Bunnings Team Member
Bunnings Team Member

Re: Large hole in door

Hi @Jay_11 

 

I'm a bit old school when it comes to painting and I prefer my primer separate from my paint. You can always ask the paint specialist at the store for a second opinion about the products. In regards to paint matching, it's best if you bring a sample of the colour you're after and the paint team will try their best to colour match it. 

 

Using a water-based primer and topcoat is always more convenient as you don't have to use turpentine to clean up paint spills and brushes.

 

Keep us updated with your progress, we look forward to seeing your door installed and freshly painted.

 

Eric

 

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