How to Fix a Hole in a Hollow Door
Hollow core doors are as the name suggests, hollow in the middle. Door manufacturers build a frame and adhere a thin veneer panel, known as lauan over the framework to create a lighter and less expensive interior door. From a distance the average eye cannot tell if the door is solid or hollow, which allows the door to blend well with the home’s décor. Hollow car doors can only be used as interior doors because they cannot stand up to changing weather conditions and they are not strong enough to provide security. Hollow core doors are prone to dame, namely holes when handled roughly or due to impacts. A hole in a door severely detracts from the beauty of the home and just looks terrible. Repairing the door rather than replacing it is a fairly easy door it yourself type project.
Fixing and Filling the Door Hole
Pick the loose broken pieces off the door by hand. Wear gloves to protect yourself from splinters or cuts from the sharp lauan edges.
Wrap 100-grit sandpaper around a sanding block and sand the edges of the hole until they are smooth.
Sand the face of the door 2 to 3 inches around the hole until you remove the paint or polyurethane finish.
Wipe the area surrounding the hole with a tack rag to remove small, splinters of wood.
Spray an all purpose cleaner onto a rag and clean the sanded areas to remove grease, dust and grime.
Add the straw-like piece into the nozzle of a can of spray foam insulation.
Put the nozzle into the hole in the door.
Spray the expanding foam into the hole until the foams expands through the hole and sits about 1/8 inch above the surface of the door.
Allow the foam to dry and harden for approximately one hour.
Equip a metal scraper with a razor blade.
Run the scraper over the repair to shave the built up foam off the door until the foam is even with the door’s surface.
Dip a thin blade putty knife into drywall compound and spread a thin layer over the repair. Pull the joint compound from the insulation outward onto the area of the door that you previously sanded. As you pull the joint compound from the repair onto the surface of the door press down firmly and use less and less compound so the application is paper thin.
Let the compound dry for one to two hours to harden and set.
Wrap 220-grit sandpaper around the sanding block and sand the patch until it is smooth and even with the surrounding surface.
Wipe the entire door with a tack rag to remove the dust from sanding.
Prime and paint the entire door to hide the repair.