How to Fix a Sliced Door

Doors are vulnerable to any exterior pressure. A kick or punch can result in a nasty hole or slice through the door. A slice can seem impossible to fix, especially in a hollow core door. Unlike solid doors, hollow core doors have nothing but air between the door shell. The air inside doesn't make a decent surface, or anchor, in which to start the repair work.

Paper
Wood putty
Plastic putty knife
Aerosol low-expanding foam insulation
Utility knife
Polyester resin
Medium-grit sandpaper
Joint compound
Primer and paint, or stain
Paint brush or cloth

Instructions

- 1
  Stuff paper into a medium-size or large slice. If the slice is less than 1/2 inch tall, fill it with wood putty, smooth the putty over the slice with a plastic putty knife and skip to Step 3.
- 2
  Fill the hole with aerosol foam insulation and press it in firmly with a putty knife. Trim off the excess insulation with a sharp knife.
- 3
  Mix the polyester resin with the catalyst; follow the manufacturer's instructions. Then apply the polyester resin to the slice in the door with a putty knife. Trim off the excess with a utility knife after the resin has become rubbery.
- 4
  Sand the surface smooth using 100-grit sandpaper.
- 5
  Smooth joint compound on the slice using a wide putty knife.
- 6
  Sand down the dried wood putty and any other uneven areas of the door with a piece of medium-grit sandpaper.
- 7
  Apply one coat of primer on the door with a paint brush, if painting. After the primer is dry, apply one coat of paint. If the door is stained, reapply the same stain, or a different one, to the door with a rag to ensure even coverage. Allow the first coat of stain to dry before applying an additional coat.

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