European hing hole...oops

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Forum topic by Jopldangla posted 11-24-2020 07:19 PM 343 views 0 times favorited 9 replies Add to Favorites Watch
View Jopldangla's profile


43 posts in 97 days

11-24-2020 07:19 PM

I was building some cabinet doors and on one of the doors I accidentally drilled the 35mm hole too deep (in fact, I punched a hole through the entire piece.. embarrasing…I know).
In an attempt to not have to remake the entire door I filled the hole in with wood filler and redrilled the hole. fine.
The issue is, it doesn’t appear to be holding well enough as when I applied the paint finish you can still see some small cracking in a circular shape.
What other options can you suggest vs remaking the whole door? Is epoxy better? Should I get a larger forstner bit and drill a larger exterior hole and fill to that? Will it not matter, because the hinge is there and nothing I will do will ever stop it from cracking? Your ideas are greatly appreciated.

9 replies so far

View waho6o9's profile


8964 posts in 3545 days

#1 posted 11-24-2020 07:21 PM

What material is the stile made out of?
A picture may be useful as well.

View Madmark2's profile


2048 posts in 1556 days

#2 posted 11-24-2020 07:25 PM

Quit dicking with it and remake it. Its never going to look right.

-- The hump with the stump and the pump!

View Loren's profile


10921 posts in 4616 days

#3 posted 11-24-2020 08:48 PM

If remaking the door isn’t an option at present, perhaps routing a rectangular hole for a patch would allow a very exacting fit. Maybe it will look right, maybe it won’t. Look at it as an experiment if you can’t do it over.

Some wood fillers are made for hardness rather than ease of sanding. I use one called “Durham’s Rock Hard Water Putty” which is said not to crack or shrink. It is not rock hard but certainly harder to sand than more common wood fillers.

View therealSteveN's profile


6971 posts in 1542 days

#4 posted 11-24-2020 09:08 PM

Yes, as a filler Durhams is the best for wood. I don’t have lab analysis but at least 50 times better/harder than bondo. It dries well enough, and solid enough you can drill it. I would be surprised if you would see the line around the edge, but even as good as it is, you would know it had been fixed. There is just something a plug always seems to show, even through paint.

I don’t think a plug of anything, even Durhams is going to look the same as a remake though, so for that I tend to agree with Mark.

-- Think safe, be safe

View a1Jim's profile


118153 posts in 4545 days

#5 posted 11-24-2020 09:14 PM

Wood filler will not hold for sure and most patches even if the hold will look like what it is,a crappy patch. If you don’t want to remake the door , just replace the stile, far less work than starting over unless you have more material already milled for the stiles and rails?


View Jopldangla's profile


43 posts in 97 days

#6 posted 11-24-2020 09:21 PM

I think you guys all answered my questions…. time to remake the door. The material is poplar. I will probably just install what i have now (with the line showing) and remake the door when i get to it. I don’t have a jointer/planer at home so I will have to go to the wood shop to get the door made to match. Perhaps I can remake the style, but I am afraid that the glue will make it impossible.
It is a shaker style door btw.

View SMP's profile


3171 posts in 874 days

#7 posted 11-24-2020 09:22 PM

Durhams or MH Ready patch work well enough. The trick is multiple thin applications, sanding between. If done right before painting you won’t be able to tell. Its good practice and if you don’t like it, and end up remaking it, you spent 10 minutes practicing a new skill.

View Rich's profile


6390 posts in 1558 days

#8 posted 11-24-2020 10:53 PM

Since the door is painted, there’s no reason to build another one. Epoxy putty will outperform any of the water-based fillers mentioned previously. One in particular that would be very easy to work with is System Three SculpWood Putty.

Since it cures rather than dries, there would be no need to apply it in layers. If you leave it slightly proud of the surface, then you will be able to sand it flush, and there will be no line visible at all. It’ll hold just fine, but creating some small indentations on the inside walls will give it a mechanical grip as well. Just three or four shallow dents you can make with a drill bit will do. Maybe 1/16 to 1/8 inch deep.

You can watch a SculpWood Putty video on the System Three web site to see if you feel it’s something you’re willing to try. I know Woodcraft sells it if you have a store in your area.

-- Half of what we read or hear about finishing is right. We just don’t know which half! — Bob Flexner

View waho6o9's profile


8964 posts in 3545 days

#9 posted 11-25-2020 04:52 AM

Easy peasy, cut the stile, dowel it or domino in the new one and glue it up.

I had to remake one of my doors as well.

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