Semi-hollow doors are widely used inside houses and apartments. These relatively fragile ports can be easily damaged. If you, or someone who lives with you, cuts a hole in a semi-hollow door, you can repair it with materials available from hardware and building supply stores. You'll fill most of the hole with an expansive foam and then finish closing it with spackle; to finish, just sand and paint the door. The entire process should take about two hours, in addition to the drying time of the plastic putty and the spackle.
Steps
Part 1 of 3: Cutting and Filling the Hole
Step 1. Cut loose pieces of plywood around the edges of the hole
The hole in your door probably has loose pieces of wood around the edges. Use a utility knife to cut this material until the hole is clean and the edges smooth.
Step 2. Place some paper towel in the hole
Fill the hole with 3 or 4 sheets of paper towels; they must be secure and cannot slide inside the door. You will need paper towels to support the expanding foam that will be added to the hole. Without the paper towel, the foam will run down the inside of the door.
Towel paper is light enough to support its own weight through contact with the inner walls of the door
Step 3. Fill the hole with expansive foam
This material comes in an aerosol can with a long plastic applicator. Apply a large amount into the hole so that the foam expands and fills the empty space inside the door. Allow the foam to dry. This will take several hours, so it's best to let it dry overnight.
You can buy expansive foam at any hardware or building supply store. If your store has a lot of options, opt for a low-expansion foam. This type of foam will make less mess after drying
Part 2 of 3: Applying Plastic Putty
Step 1. Cut the protruding foam
Once dry, the foam will have expanded significantly, which can generate excess material on the door. Using a utility knife, cut off excess foam until it is slightly lower than the surface of the door.
Expanding foam needs to be completely dry before you cut it. If the center of the foam is still wet, wait a few hours until it is completely dry
Step 2. Mix the plastic putty and a hardening catalyst in a 2:1 ratio
Put some plastic dough in a plastic bowl or tray. Then throw in half that amount of hardening catalyst. This material should harden and quickly cover the outside of the hole in the door. Both materials have a thick, viscous consistency; use a popsicle stick to stir them until the two substances are completely mixed.
- Start with a teaspoon (5 ml) of plastic putty and half that amount of catalyst. Add a little more to the mix if needed.
- Both plastic putty (such as 3M's Bondo) and hardening catalyst can be found in major home improvement stores. If you can't find them, look for these materials at automotive equipment and accessory stores.
Step 3. Apply the mixture over the dry foam
Take some of the mixture with your Popsicle stick and spread it over the dry foam filling the hole in your door. This material will dry and harden quickly, so you must work quickly.
- After about 5 minutes, with the mixture starting to thicken, use a spatula to scrape it over the door. This will smooth the surface and remove excess material.
- Wait for the mixture to dry completely to continue the process.
Step 4. Sand the mixture with a #100 sandpaper
Sand the dry mixture until the surface is completely smooth and aligned with the port. Also, use sandpaper to remove any excess foam or plastic putty mixture that may have been left around the edges of the hole.
Sandpaper of various numbers can be found at home appliances or building supply stores
Part 3 of 3: Putting Putty and Painting the Hole
Step 1. Apply the spackle over the plastic putty mixture that has been sanded
Use a spatula to apply a layer of spatula over the hole. Use long, smooth strokes so that the dough is even and well spread out. Let the spackle dry after applying it; this should take about an hour.
You can find spackle at any building supply store
Step 2. Sand the hole once the dough is dry
Rub sandpaper over the dry spackle until the surface is completely smooth. You can also use #100 sandpaper for this task. However, use a different piece of sandpaper than the one you used in the plastic putty mix.
Step 3. Apply a coat of paint over the hole
The spackle is already dry and sanded, so you only need one step to complete the hole repair. Use a large brush to apply a coat of paint over the patched hole. Use long, smooth strokes so that the paint layer is as even as possible. Now just wait for the paint to dry completely - which should take about an hour - and your job is done.