How to Plug a Hole in a Cabinet Door

The secret to plugging holes in a cabinet door is to completely fill the hole with something, be it wood putty, a narrow dowel, or even toothpicks, and then sand and refine to create a perfectly level surface. Follow these suggestions to plug unsightly holes in a cabinet door prior to mounting new hardware, or to fix a screw hole that has worn and become stripped.

Step 1: Smooth the Rough Edges of the Hole

Sand the hole edge to remove all chipped paint, varnish, and splinters. Use the coarse-grained sandpaper first, then polish up with the fine-grained paper.

Step 2: Mix the Wood Epoxy Filler

Wood epoxy filler comes in two separate parts. Mix these components together in a stainless steel or ceramic bowl and set it close to your work area. Work quickly because the wood filler dries quickly once it is exposed to the air. Always work with wood epoxy filler in a properly ventilated area. Use a fan in a small space to direct fumes away from you.

Step 3: Fill the Hole with Wood Material

For a hole less than ½ inch in diameter, use toothpicks as your filler material. Dip the broad ends of the wooden toothpicks in the wood filler and insert them into the hole. Keep adding more toothpicks until the hole is completely filled to its edges. Use another toothpick to add more wood filler between toothpicks up to the surface of the hole so there are no gaps. Work carefully with the wood epoxy filler so it does not drip or make specks on the door surface.

For larger holes from ½ inch across up to 1.5 inches, use a wood dowel or a wooden cork, or custom cut a piece of wood to fit the hole. Line the hole with a thin layer of wood epoxy filler, insert the wood plug, and add more wood filler to fill the hole to surface level.

Step 4: Allow the Wood Epoxy Filler to Dry Thoroughly and Snap Off Toothpicks

Once the wood epoxy filler has dried to a solid finish, carefully snap off the toothpicks, or cut them with a pair of small shears. Do not tug or bend the toothpicks while removing their tops.

Step 5: Sand the Filled Hole Level and Refinish as Needed

Use both types of sandpaper to smooth off the filled hole. If you can still see toothpick points apply a thin layer of wood filler across the hole. If you are attaching door hardware at a new location, refinish the surface of the hole with wood stain, varnish or paint to match the rest of the door surface. If you are going to reaffix the hinge or handle at the location of the hole, you will not need to do any refinishing.