How to Patch a Wood Veneer Door

Tools:

sawhorses
flat-head screwdriver
hammer
utility knife
ruler
pencil and pen
cardboard
masking tape
wood chisel
medium-grit sandpaper
wood glue
towel
gloves
piece of replacement veneer
stain or paint supplies (optional)

1. Remove the door from the hinges using a screwdriver and hammer (figure A) and place across sawhorses.

2. Measure the size of the hole and draw a light reference line on the door bisecting the hole (figure B).

3. Draw an irregular shape large enough to encompass the hole on a lightweight piece of cardboard (figure C). Make the shape about 1/2-inch beyond the dimensions of the hole. The reason you want an irregular shape is that a square or circular patch on the veneer would be much more noticeable. A football-shaped patch works well.

5. Place the cardboard shape over the hole in the door and line it up with the reference line (figure E).

6. Score along the edge of the cutout (figure F). Go just deep enough to score the veneer, do not try to cut through the door, and be sure not to cut into the cardboard.

8. Carefully deepen the score line on the door a bit, cutting just through the top layer of veneer.

9. Now use a chisel to remove the top piece of veneer within the scored area (figure H). Take a piece of medium-grit sandpaper and smooth out the exposed area.

10. Hold your piece of replacement veneer up to the hole and try to match the grain pattern with that on the door (figure I). You probably will not match it perfectly, just get as close as you can. Stick your cardboard template on the area of veneer that matches best.

12. Test fit the patch on the door and if it fits then coat the back of the patch with all-purpose glue (figure K). Spread the glue out in an even layer.

13. Stick the patch on the door, twist it slightly to work it securely into place, cover with a piece of plastic and place a heavy book on top (figure L). Allow the glue to set for 30 minutes.

14. Sand the patch to smooth the edges. Use a light touch and sand with the grain. Touch up with a light coat of stain and give it a few minutes to dry (figure M). Just replace the door and be amazed at the nifty, almost invisible patch.