For durability and structural integrity it s hard to beat real wood when filling a large hole in a door.
Patching door lock hole for reuse.
Remove the old lock if it is still installed.
Allow the glue to dry overnight.
Replace the plate fill the gap at the top or bottom with wood putty and refinish.
Inject a liberal amount of foam to be sure the entire area under the damage is filled.
Cut away ragged edges around the hole using a sharp utility knife the kind with retractable snap off blades.
If the latch still will not reach shim out the door s hinges.
Repairing a hole in exterior wood doors.
If the latch does not reach the strike plate shim out the plate or add another strike plate on top of it remove the screws and run them through both plates.
For wood doors that are solid or when the unwanted hole is in an area of the door that is solid the most effective technique to repair the unwanted hole is to cut a piece of dowel that is the same diameter of the unwanted hole slightly longer about 1 32 inch than the thickness of the door.
A dowel of the proper diameter works well for the rounded hole in the door edge left by the.
Remove the set screw under the edge of the inside handle and pull both knobs from the door.
Remove the four corner screws from the plate on either side of the door and pry the plates away gently with a flat screwdriver blade.
Tap the dowel plug into the hole as far as possible aligning the grain pattern of the dowel rod vertically.
Apply glue to the interior of the hole.
Step 1 remove any loose pieces from around the hole.
Use your utility knife if needed.
Step 2 stuff some paper towels down inside the hole.
Hold the knife at a slight angle to create a beveled cut and use a gentle sawing.
This will provide a ledge of sorts for the foam insulation to sit until it is dry.