Patch Door Hinge Mortise

Tools:

portable workbench
spring clamps
utility knife
combination square
pull saw
tongue depressor
hand plane
hammer
rasp
sandpaper
chisel
dust mask
rubber gloves
safety glasses
1/4-inch paneling (small piece)
piece of cardboard
spray primer
epoxy

1. Put on a dust mask and safety glasses. Use a rasp to remove just enough material to expose the outline of the old mortise (figure A).

2. Mark the outlines of the mortise by pressing the chisel into the surface, then use a hammer and the chisel to remove the filler. Be careful to remove only the filler and not the doorframe around the mortise. Finish cleaning up the area with the rasp (figure B).

3. After removing any ridges or bumps with the rasp, smooth the area out with sandpaper.

4. Measure for your mortise patch using the combination square (figure C). Record the measurements.

5. Repeat the process on the lower mortise.

6. Transfer the measurements to the 1/4-inch paneling. For greater precision, use a utility knife to mark for the cuts (figure D).

7. Cut the patches using a pull saw.

8. Test fit the patches (figure E). Use epoxy to glue the patches into place. Wear rubber gloves to protect your hands while working with epoxy.

9. Let the epoxy dry for about five minutes, then come back and use a hand plane to cut away excess material and leave the patch flush with the doorframe. Smooth it all out with sandpaper.

10. Paint over the patches with a spray primer/stain blocker. Hold a piece of cardboard next to the patch to shield the surrounding areas (figure F).

11. Let the primer dry for at least an hour, then apply a second coat of primer. Paint the next day if desired.