How to Fix Gouges in a Wood Door

Both the wood veneer covering hollow core doors and the surface of solid wood doors require protection from moisture to ensure the door does not rot. Deep gouges not only look unsightly but also allow water to pass by the protective layer holding rot at bay. Correctly repairing a gouged wood door will increase its lifespan. Although common wood fillers make a strong repair, many still absorb water and allow moisture to pass into the interior structure of the door.

1/4-inch chisel
80-grit sandpaper
Clean rag
Polyester epoxy resin
Wood stir stick
Putty knife
120-grit sandpaper
220-grit sandpaper
Paint or wood stain
4-inch paintbrush
Foam-padded roller cover

Instructions

- 1
  Pull the beveled side of a 1/4-inch chisel along both sides of the gouge until all large splinters are removed from the door.
- 2
  Fold a piece of 80-grit sandpaper in two. Ensure the smooth sides of the paper are facing in. Push the rough exterior side of the folded sandpaper in the gouge. Move the paper back and forth to sand down all rough wood. Clean the gouge with a clean rag.
- 3
  Mix equal portions of part a and part b of a polyester epoxy resin on a clean surface with a wood stir stick. Apply the epoxy resin to the prepared gouge immediately after mixing with a putty knife. Ensure the epoxy protrudes 1/16 inch above the surface of the door. Allow the resin to dry for 15 to 30 minutes.
- 4
  Sand the epoxy level to the surface of the door with a piece of 120-grit sandpaper. Remove sanding marks from the door by sanding over the repair with a piece of 220-grit sandpaper.
- 5
  Apply an even coat of paint or wood stain to the surface of the door with a 4-inch paintbrush or a foam-padded roller cover.

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