Help Around the House host Henry Harrison shows how to patch a hole in a hardwood floor by cutting a plug from salvaged lumber. On his elbow grease scale of one to four, Harrison gives this job a two.
Tools:
oak (salvaged scrap)
wood glue
work bench
rubber mallet
compass
pull saw
duct tape
clamps
tape measure
file
coping saw
sandpaper
power drill with a wood-boring bit
safety glasses
Steps:
1. First roll up sandpaper and sand inside the hole. Then brush away any debris for a clean fit later. Be sure to wear safety glasses while sanding, sawing and drilling.
2. Measure the width of the hole and use a compass to draw a circle 1/16th of an inch wider onto a piece of lumber of the same kind as the floor (figure A).
Henry had two tips for this part of the job. One, when measuring the hole, start at the 1 instead of the end of the tape measure or ruler (figure B) for a more accurate count--just remember to subtract one from your final measurement! And secondly, if you have a few pieces of wood to choose from, lay them out on the floor near the hole and choose the one that matches best (figure C).
3. Using a power drill with a wood-boring bit, drill a series of holes around the perimeter of the circle, taking care not to get inside the lines (figure D) . Angle the bit slightly so that the base of the plug is smaller than the top, like a cork. An easy way to make sure that you don't cut inside the lines is to lay the drill bit flat on the wood until the edge of the bit is at the edge of the line. Then raise the drill up, keeping the tip in the same place, and you'll know how far your bit will cut (figure E). Be sure to wear safety glasses while sawing and drilling.
4. Use a coping saw to cut between each hole, leaving a plug with ridges on the sides (figure F).
5. Cut off the large ridges with the coping saw (figure G).
6. Shave down the ridges with a file.
7. Sand down the ridges till the plug is fairly round (Tammy used an 80 grit sandpaper).
8. Test fit the plug; then sand and test again as necessary until the plug fits snugly into the hole, protruding just slightly above the surface. Try to match the wood grain of the plug with the surrounding area for the best appearance.
9. Apply glue to the outside of the plug and place it in the hole.
10. Hammer it in with a rubber mallet and allow the glue about an hour to dry.
11. Place tape around the outside of the plug to protect the floor. Press a flexible pull saw flat against the floor so its blade is even with the surface (figure H). Saw the top of the plug off even with the floor and remove the tape.
12. Sand the surface with the 80 grit sandpaper, being sure to sand with the grain of the wood.
13. Clean the area with paint thinner and finish or stain the area as best you can to match the surrounding floor.
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