How do I repair a solid wood interior door that has a large chunk of the botton corner missing?

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remove door draw straight line 1\8 th " past all damage continue line up till it passes the top of the damaged area by about 3\8th", now mark down to the end of the damage on the outer edge of the door looking from the top to the bottom of the door your marks should resemble a tick now carefully cut out the damaged timber using saw and chisel making sure the cuts are square and true . now take a piece of the same type of timber slightly wider thicker and longer than the piece removed place it under the door with its good edge against the new edge where you have removed the damaged timber till it passes the top of the removed piece "sharp pencil "draw the angle you created in the door onto the wood ,trim this off with saw test patch in door for fit using strong wood glue, and insert into door if you have clamps clamp it in place Or tape it in place allow glue to set completely trim and sand exes of timber, and refinish door varnish \ paint .
don't you just hate it when people say that you cant do that !!...Show more

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It can be repaired, but may take some talent.

I've been able to match finishes myself, so I can't be told a piece of wood 'cannot be repaired'. But I will admit that not everyone can do it.

I would get a piece of wood of the same species, and as close to the grain and color as the section that is damaged. Using one joinery technique or another (can't say which because youve not given us enough information), I would glue the new piece of wood to the door, trimming and sanding it to match. Then refinish that portion of the door. Some folks would opt to refinish the whole door, as that would be slightly easier than trying to match an existing finish.

This is probably not the best project for you to begin practicing woodworking and refinishing on. I'd suggest that you send the door out to a furniture repair shop, or a custom cabinet builder - Those are the two places you will most likely find the combination of skills, tools and supplies at.

Good Luck...Show more

Yes, a bit large for wood putty, but not too big for automotive body putty. It sets up fast and can be shaped any way you need it... and it really sticks to rough wood.

I would build a frame or mold first & attach it to the door. In other words, cut 2 strips of wood the same width as the door is thick, and about 16" long. Attach one down along the side, & the other across the bottom to butt up against the one on the side. Then put a piece of celophane under the open area needing rebuilt, and around the slats. This will prevent the filler from sticking to your worktable, and allow you to remove the slats easily. Last, mix up enough filler to fill the hole & go to it.
Once the body filler has set up (about 10 min.), remove the slats & sand any high points or rough edges. Paint it & you're done.
I've used this technique on a variety of wood repairs and it works great.

P.S. If both edges of the hole are rough, the putty will grab on well. If the edges are smooth, I suggest pounding some nails in about half way - on both the horizontal & the verticle edges.
This will act like rebar in cement & give the putty something to grab on to. Good Luck!...Show more

Considering the cost of a new solid door.......
Couple of options,
If it is a hardwood door w/ a natural finish , you could try to find matching wood , make a diagonal cut to clear the damaged area & glue & screw or dowel on a patch.
If it is painted , same approach , but you will not have to worry about grain matching & a little filler would be ok.
Best regards...Show more