How to Repair a Hole in a Hollow Door

Written by robert ferguson
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How to Repair a Hole in a Hollow Door
An interior door is easy to fix. (Jupiterimages/ Images)

Hollow core doors are an inexpensive alternative to solid core doors for interior applications. Manufactured by wrapping a frame reinforced with structural paper or foam blocks with wood laminates, the doors are easily damaged. Repairing a hollow core door is an easy do-it-yourself home improvement project that will take approximately one hour to complete.

Skill level:

Things you need

  • Dust sheet
  • Spray foam
  • Flat razor blade
  • Plastic filler compound
  • Putty knife
  • Sandpaper
  • Primer
  • Paint

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  1. 1

    Place the dust sheet under the door to protect flooring. The spray foam is very messy and hard to remove from some surfaces.

  2. 2

    Fill the hole in the door with the spray foam. Apply a generous amount to the inside of the door's cavity to strengthen the area around the hole. Allow the foam to expand beyond the door's surface and dry overnight.

  3. 3

    Shave the foam using the flat razor blade. Remove the foam to a level just below the door's surface. This provides a solid foundation to hold the plastic filler compound.

  4. 4

    Fill the damaged area with a plastic body filler or putty. The filler mixes with a hardener that activates it. Fill the damaged area using a putty knife and allow it to dry.

  5. 5

    Sand the damaged area with fine sandpaper. Prime the entire surface of the door with an applicable primer and allow it to dry. Paint the door with a suitable finish paint to complete the project.

Tips and warnings

  • Wear disposable plastic gloves when working with spray foam. It is difficult to remove from exposed hands.
  • Although this method will work for a stained or varnished door, the patch will remain visible after completion.
  • Follow manufacturers' directions and warnings on spray foam can.
  • Use paint and spray foam in well-ventilated areas.

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