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Old-House Online » Old-House Tips, Restoration Stories, & More » Repairs & How To » Fix a Door Panel in 4 Steps

Fix a Door Panel in 4 Steps

A reader shares his step-by-step method for repairing a panel that's been knocked out of the door.
Story and photos by A.R. Bowes

    The damaged panel had previously received a hasty repair.

    The damaged panel had previously received a hasty repair.

    On this door, a raised panel had been knocked out, breaking the panel itself and tearing out chunks of the rails above and below the panel. The area at the bottom of the panel was extensively damaged. A large splinter was broken off the panel, and another strip along the right side of the panel had also been broken off and was missing. Whoever nailed the broken pieces back together also lost some splinters that could have been glued back in place. The ovolo profiles were broken, and portions were missing. The corresponding area above the panel was similarly damaged.

    Step 1

    The damaged portion of the rail above the panel is chiseled out in preparation to receive the replacement piece.

    Chiseling out the damaged wood

    Step 2

    New wood is planed to fit in the rail. Inconsistent profiles can make it hard to find a matching router bit or molding plane. A small shoulder plane was used to fine-tune this ovolo.

    Planing the new profile

    Step 3

    Each replacement piece was carefully fitted to avoid unnecessary sanding, and one end was coped to match the profile on the stile.

    Replacement wood on the rail

    Step 4

    The the large splinter is glued back into place, and new wood is added on the opposite edge edge. The panel is now ready to be fitted back into the door.

    The repaired panel
    Published in: Old-House Journal June/July 2013



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