How To Patch a Hole in Wood Trim

Whether you’re dealing with damage from furniture moves, pet scratches, or accidental impacts, knowing how to patch a hole in wood trim can save you time and money. In the video above, This Old House expert Tom Silva teaches a clever technique for creating an undetectable patch in baseboard trim using a router and a custom-made jig.

Understanding the Dutchman Technique

The method Silva uses to patch the hole in the baseboard is called the Dutchman. This technique involves creating a custom-fit patch that sits flush with the surrounding wood surface, resulting in a nearly invisible repair.

When To Use a Dutchman Patch

A Dutchman patch is ideal for areas that require structural integrity, high-visibility locations with a highlighted appearance, and large holes or gouges in wood trim.

Preparing for the Repair of a Wood Trim Hole

Before diving into the patching process, gather the necessary tools and materials and prepare your workspace.

Tools and Materials Needed

To complete this project, you’ll need the following tools and materials:

• 3/4-inch wood chisel
• 1/2-inch-thick poplar board
• 1×2 and 1×4 lumber for the jig
• 2-inch finishing nails
• 120-grit sandpaper
• Carpenter’s glue
• Drop cloth
• Hammer
• Instant-bond glue and accelerator
• Primer and paint to match the trim
• Random orbit sander
• Table saw
• Trim router
• Wet/Dry vacuum

Setting up Your Workspace

Perform the following tasks to prepare your workspace:

1. Lay down a drop cloth to protect the floor near the repair area.
2. Make sure you have adequate lighting to see the details of your work.
3. Set up your tools within easy reach of the repair site.

Creating the Custom Jig for a Dutchman Patch

The key to a successful Dutchman patch is a well-made routing jig. This jig will guide your router to create a perfectly sized recess for your patch.

Cutting the Jig Components

Cut the jig components as follows:

1. Cut two pieces of 1×2 lumber for the top and bottom of the jig.
2. Cut two pieces of 1×4 lumber for the sides of the jig.
3. Check that the center opening of the jig is slightly larger than your poplar patch.

Assembling the Jig

After cutting the jig components, you can assemble the jig:

1. Apply instant-bond glue to one surface of each joint.
2. Spray the mating surface with an aerosol accelerator.
3. Press the pieces together and hold for several seconds until the glue cures.
4. Sand the front and back of the jig using a random-orbit sander with 120-grit abrasive.

Cutting the Patch

The patch itself is a foundational component of the repair. It should be slightly larger than the hole you’re repairing and made from a material that matches the existing trim. For this repair, Silva uses a 1/2-inch-thick piece of poplar.

Sizing the Patch

Measure the patch as follows:

1. Measure the hole in the trim, including any damaged areas around it.
2. Cut your poplar patch about 1/4 of an inch larger on all sides than the measured area.
3. Check that the patch is thick enough to sit flush with the trim surface when inserted.

Routing the Recess in the Trim

With your jig and patch prepared, you can create the recess in the trim that will house your patch.

Positioning the Jig

Center the jig over the damaged area of the trim. Then, secure the jig to the trim using two-inch finishing nails, leaving the heads protruding for easy removal.

Setting up the Router

To set up the router, install a half-inch-diameter-by-one-inch-long pattern-cutting bit into your trim router. Adjust the depth of the cut to equal the thickness of the jig plus the thickness of the poplar patch.

Routing the Hole

Next, route the hole by turning on the router and holding it flat against the jig. Move the router clockwise around the jig’s opening, keeping the bit’s bearing pressed against the inside edge. Have a helper collect the dust with a wet/dry vacuum as you work.

Finishing the Recess for Your Patch

After routing, there are a few final steps to prepare the recess for your patch.

Squaring the Corners

Square the corners as follows:

1. Use a 3/4-inch wood chisel to square up the rounded corners left by the router bit.
2. Tap the chisel gently with a hammer to achieve clean, sharp corners.
3. Carefully remove the nails holding the jig in place using the claw end of your hammer.

Installing the Custom-Cut Patch

With the recess prepared, you can install your custom-cut patch.

Applying Adhesive

To start the installation, apply a thin, even layer of carpenter’s glue to the routed recess. Cover the entire surface, including the edges and corners.

Inserting the Patch

Next, press the poplar patch into the glued recess. Gently tap the patch with a hammer until it’s fully seated and flush with the trim surface. Immediately wipe away any excess glue that squeezes out with a damp cloth to prevent it from drying on the surface of the trim.

Finishing the Repair of a Hole in the Wood Trim

The final steps will make your patch indistinguishable from the surrounding trim.

Sanding the Patch

To start the finishing touches, sand the patch:

1. Allow the glue to cure for about 2 hours.
2. Use a random-orbit sander with 120-grit paper to sand the patch flush with the trim.
3. Pay special attention to the edges where the patch meets the original trim.

Filling Any Gaps

If you notice any gaps, you can fill them with carpenter’s glue. Allow the glue to harden, then sand the area.

Priming and Painting

Silva demonstrates that using proper techniques and tooling can transform any damaged baseboard into a flawless surface, ready for painting. Here’s how to prime and paint the repair:

1. Wipe away all sanding dust with a damp cloth.
2. Apply primer to the patched area and let it dry completely.
3. Paint the patch to match the surrounding trim, feathering the edges for a seamless blend.

Tips for Best Results for a Seamless Patch Repair in Wood

Achieving a seamless patch repair in wood trim requires both patience and precision. Here are some additional safety tips to receive the best results:

• Always use sharp tools: Dull tools can create ragged edges and lead to imprecise cuts.
• Maintain a steady hand: When routing and chiseling, keep a steady hand to create clean, straight lines.
• Practice on scrap wood: Before making cuts in your actual trim, practice with scrap pieces to perfect your technique.