I want to fill in the door knob hole in a solid wood door!

Question

What can I use to fill in the door knob hole in a solid wood door? I want to sand it afterwards as though the hole did not exist! Thanks Shirley

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Woodbridge Environmental Tiptophouse.com · Answer

Although this can be a bit tricky to do, its not all that hard. 
You first need a block of wood that is the same as the surface of the door, Unless your painting it. It needs to be at least as thick as the door also. 
Your going to drill out using a hole saw drill bit a plug of wood out of the block of wood. This hole saw should be the next size larger then the hole that is currently drilled in the door. 
Once you have successfully drilled out the block and removed the plug from the bit, you will notice a small 1/4 inch hole in the center. Take a long 1/4 inch bolt that should just fit in that hole and using washers and a nut fasten it to the plug. Leaving about a inch sticking out on one end that can be put back into the drill. 
If you have a drill press this part is easy, if not using a hand drill will still work. 
Put the plug In the drill after first trying to fit the plug in the hole. It should not fit just yet. Once in the drill turn the drill on and using sand paper place it against the moving plug. This will remove an even amount of wood off of the plug all the way around. Keep testing the plug to it just fits in tightly. Once done, spread some good quality wood glue on the plug and inside the hole and push it in so its evenly sticking out on both sides. Pay attention to the grain on the plug so it matches up with the door. Do this before pushing it in. As once its in, its not coming out or turning. 
After the glue dries, using a belt sander or vibration sander remove any excessive plug material that is sticking out of the center of the door. With the small hole in the center, you can purchase a round dowel that will also fit in the small hole like the plug did and cut it off and sand it smooth.

Z · Answer

My first thought was to make a round plug using a hole saw as Bob said, but because you won't be able to easily match it's size, I put my thinking cap on. After a bit I wondered if it wouldn't be better to cut the hole you want to fill into a square, then make a square plug. It should be easier to get that to fit. Ofcourse this depends on what tools you have.
What do you think @Bob? Example shown below....

Jeanette S · Answer

Why not fit a plug into the hole...one that fits really tight...one that is slightly less thick than the door. then wood putty it in an working the putty onto the inside and outside of the door slightly...then sand smooth and paint? Wouldn't the putty hold the plug in place? It is not a matter of security because most doors themselves are not too sound against entry anyway.

Woodbridge Environmental Tiptophouse.com · Answer

There are other methods of repair and various amounts of difficulty in these repairs as well. Depending upon the type of door were talking about and exactly the reason why the door needs to be fixed?

Tasha @ Designer Trapped In A Lawyer's Body · Answer

Hi Becky! My husband I have done this using an expoxy product. It was relatively easy to do. This is probably not the best tutorial, but it will get you started if you want to do a google search to learn more about the process. Unfortunately, we did this project before I started blogging, so I don't have my own tutorial for you. Good luck! http://homeguides.sfgate.com/filling-holes-wood-project-epoxy-glue-sawdust-85564.html

Woodbridge Environmental Tiptophouse.com · Answer

If the door was to simply going to be used for a decorative use and it was going to be painted. Simply use auto body epoxy filler and fill the hole with it and paint after sanding. Quick and easy.

Sharon T · Answer

I would use a dowel the same size as the hole and use wood glue to keep it in place. You may have to find one and sand it to fit. At least that is what I am planning to do on a lovely door I found.

Christine · Answer

I've also seen this done on blogs with painter's tape blocking the hole, then laying it flat on something so the tape won't move. Fill the hole with either epoxy, that builder's putty (that escapes me right now) or something that won't shrink. Scrape it almost flat, but just not quite. You'll have to let it dry for a LONG time, I'd think, or it'll be soft in the middle. I've used caps and on a couple, just pocket door pulls that fit into the hole. I aged them and no one has ever noticed them.

Bridget Leblanc · Answer

Abatron wood restore kit...it is epoxy based and can be sanded stained or painted. It dries hard as the wood.

AudraB · Answer

I recently had to do this for a couple of our doors. I just used a dried tree branch that was the same diameter I needed, cut it to the correct depth with a handsaw, and whittled the edges, so it fit snugly in the hole.

Michele · Answer

you can use wood putty

Patty Winchell- Yettaw · Answer

I too am having this problem. Trying to find something that’s not ugly or super expensive. I came up with a set of round wood appliqués I bought from Micheals craft store on clearance for $0.49! Just make sure it is bigger than the hole and glue in place. Stain or paint!

Tommy Dwyer · Answer

“Little outside the box” ...I used my old solid door that swung open to a pocket door. The door slides in flush so had to remove the door knob . Lucky for me I had an old wood baseball bat . Slid it in till snug , marked it , cut it , tapped it in place nice and snug , a little putty and paint and it came out great, and I still have a size 30 bat for future projects !

Lynn Sorrell · Answer

piece of wood from scrap pile cut to size glue in with carpenters wood glue,piece of dowel rod or old curtain rod,baseball bat(as Tommy suggested/good idea)

Nora chavez · Answer

I'm thinking of doing that. But since I have to drill new holes on the opposite of the door for opening purposes, I plan to use the round piece I drilled out on the right side to fill the original hole on the left side. Then for the lock piece I'll just fill it with other pieces of wood. I don't have to worry about how it looks since it will be on the inside of the door facing the framing.

Nora · Answer

I have a door, circa 1910, has old Corrine Mortisse locking system with no keys , any ideas on filling in the gynormous door locking system hole to put a regular door knob in it's stead? This is an exterior door. Could an exterior wood putty fill in the area after I remove the Mortisse locks an then drill a new hole for new door knob? The replacement for this door lock system is over $800.00 so I could buy a new door, but the front door is so perfect in every way except I cant use it!!!