how to fix a hole in a hollow core door
Instead of replacing)
This is possible if you can overcome two problems that make this repair difficult.
First of all, these doors are hollow.
There is nothing behind the skin of the mid-fiber board or hard board surface of the door that can attach the patch, or provide support to prevent the patch from cracking subsequently.
Second, the texture of many hollow core doors is molded into a medium-slim or hard board, similar to wood grain.
Such a smooth patch on the door will stand out because the texture does not match.
Damage to these doors can be repaired by creatively using products originally used for other purposes.
This manual describes how to fill the gaps behind the damaged area using an insulating foam sealing material, as well as the silicone rubber mold material and casting resin to reproduce the grain texture on the patch.
The main activities required to repair the holes on the hollow core door are: Step-by-
The steps to complete these activities are described below.
Fill the hollow area behind the door plate defect with insulating foam sealant.
Insert the tube into the damaged area so that the foam sticks to the back of the other side of the door and completely fills the gap between the door panels.
Inject a lot of foam to ensure that the entire area under damage is filled.
If the door is removed and placed flat on the sawhorses or floor, it is easier.
If the door is just cracked or cracked and the nozzle of the insulating foam sealant cannot be inserted, you may need to drill holes in the door panel to allow the injection of foam.
Because the foam expands so much after the application, there is no need for many of these access holes.
When the foam expands, it is squeezed out of the hole.
This can be expected.
Don\'t let the foam drop down the surface of the door, or you\'ll make a mess.
If you have to fill the void with an upright door, use the concealer to bring the protective door.
Let the foam completely solidify (
Overnight for safety).
After the insulation foam cauldron is fully cured, it will be quite firm and will no longer stick to the touch.
Foam provides sufficient strength to prevent damaged door panels from bending during normal use.
If the panel is not supported enough, your patch may eventually break due to the constant bending and vibration of opening and closing doors.
Trim off all excess foam that protrude during expansion and curing (
Knife or saw).
Sprinkle sand in this area to make sure it\'s flat.
Dents are OK at this point, but all the highs have to be polished off.
Using epoxy filler material, apply a layer in the damaged area to fill all the low areas and combine the patch layer with the door panel surface.
Follow the instructions of the filling material you use for mixing batches.
Smooth it with a plastic spatula or similar tool.
It is best to keep the filler a little higher and polish it to the level of the door panel to avoid applying another coating.
But if the defect is too deep (
1/4 or over 6mm)
The filler manufacturer may then recommend multiple layers.
Let the filler fully solidify (
Usually 15 to 30 minutes)
If your hollow core door is smooth and flat, you are finished.
Paint the door.
But if your door has a wood grain texture, then a smooth, flat patch will still appear after painting.
Therefore, it is now necessary to reproduce the wood grain texture before painting.
Find a place on the door that is not damaged, where the wood pattern is intact.
The bottom of the door is a good place to consider, as it is usually wider than other areas, and you can create a texture mold that is wide enough to cover most of the damaged areas.
Create a frame with wood and fix it in the door area selected for the texture mold.
Clips or small nails can be used for this purpose.
Seal the cracks between the wooden frame and the door using clay or putty to prevent silicone leakage.
Level the door so that the silicone is stable in uniform thickness throughout the frame.
Follow the manufacturer\'s instructions on RTV silicone rubber, mix and pour the silicone rubber into the frame.
Vibrate the door for a few minutes to help the bubbles escape and make sure the liquid silicone permeates all the wood grain lines.
This can be done by gently tapping the lower side of the door with a rubber mallet.
Make the silicone completely cured.
See the manufacturer\'s instructions to determine how long to wait.
After fully curing, remove the frame and peel off the silicone texture mold.
It won\'t stick to the door.
The mold will create a negative relief for the wood pattern of the door.
Place masking tape around the area where the wood pattern will be created.
It\'s better to overlap the existing wood pattern a bit, so your silicone texture form should be a little longer than the patched area.
Mix the cast resin according to the manufacturer\'s instructions and apply it to a thin coating throughout the area.
This should be a thin coating. . .
The texture layer is not very thick. .
Place the silicone texture form on the resin and press it with force.
Scroll with a rolling pin (
I just used great stuff)
Going out of the center will help to squeeze out excess resin.
Use a disposable paint brush or rag to clean up the excess resin of the extruded masking tape.
Once the silicone texture form is rolled, place a tablet with a certain weight on it to maintain a strong contact with the door.
Let the resin completely solidify.
Peel off the silicone texture form and see the wood pattern in the cured resin.
Any bubble trapped in the form of a silicone texture creates a small hole in the wood pattern.
Before painting, I can fill these small holes with some caulking agent and the effect is good.
The rest is to decorate the repaired place and paint the door.
If you look closely, you can see where the textured patch edges are, but the temporary observer will not notice after launching and painting.