What's the best approach to fixing this hole?

ArcadeRu

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So there is a huge hole in the side of the cabinet I just bought (I attached pictures of the problem area inside and outside). I was thinking of removing the outside piece of wood and gluing a piece of wood on the inside and filling the gap with bondo.

Is this the best approach? Any tips? Can bondo be used to fill such a huge hole?

I'm hoping to have the hole patched up and apply new decals to make it cosmetically look new from the outside.

Looking for tips, direction, suggestions, or maybe just confirmation of what I plan on doing will indeed work and be the best approach.

I appreciate any help.

Thanks.
 

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cut out the damaged area as a perfect square using a router with a flush trim router bit and then cut out a patch using 3/4" particle board.
 
Yeah, pretty much.

Alternate: cut your patch piece then use it as a template to cut the cabinet hole with a vibrating multi tool.
 
Do NOT rely on bondo to fill a hole. It will crack, shrink etc. you will need to make a jig to cut out a square then glue in a patch that's a tight fit made from MDF. Why MDF? It's similar material and dimensionally stable. Particle board is prob ideal as it's same material, but big box PB is almost never actual 3/4". I had to make a similar repair, but on back edge of a Gauntlet cab. It's near impossible to find the repair now.
 
@joeycuda What would you use to fill the gap between patch and cabinet?
You'd glue the patch in there w woodworking glue. Any depression fill w Bondo, but should only be a razor thin skim coat of it. Primer, then a good thing is Bondo Glaze/Spot Putty. It's a red putty than you can dab on w your finger if you have to, but it fills tiny voids and dries pretty quick. May just need a skim coat of that. Prime, paint, etc.. but w sideart/decals, any screwiness under it will show thru.
 
I second the fiberglass. I'd take that external patch that you already have, remove it, then screw it to the inside of the cabinet with particle board screws of enough depth to hold things together but not penetrate the exterior of the cabinet. Use a bunch of them to pull the wood as tight to the cabinet as possible to reduce any leakage from the next step. Then lay the cab on its side, with the hole now facing up, and pour fiberglass resin into it, and let it self level. You can use the fiberglass cloth to reinforce it, but, I don't think it's warranted. So you've then got a big resin filled area that's backed by wood. Sand it flush and you've got a winner.
 
Above suggestion with backing inside of hole with some wood is excellent.
Putting some blue masking tape over the hole before the wood goes over it is even better.

Polyester resin will work but could be drama with that kind of volume.
As an upgrade to that method, use two part aluzine epoxy resin and microballoon filler mixed to a marshamallow consistency and you can leave the cabinet standing upright actually if you use enough thickener.
Won't get so hot that you get drama.
Won't crack and smoke and set off the alarms in the house.
Won't start a fire because you mixed it too hot.
Won't sag while it kicks if you get the mix right.
Sands easier than straight polyester resin (easier than bondo too) and can be top coated with ANYthing- including glazing putty next if you needed a mirror shine on it.

Not necessary here obviously, but still the best material to work with if you can stomach the details.
 
@joeycuda What would you use to fill the gap between patch and cabinet?

I don't have any pics but I used bondo glass filler to glue and feather out a hole i patched on a dynamo that had two holes for a happ gun mount. Those holes were about 2 - 2 1/2" around. Was super strong and stable. I never used any glue on it.

I just don't know how well it would hold up on a patch this big.
 
Depending on how far down the damage goes, I would go along the lines of what @DonPanetta said. I would probably make a jig to router out a perfect square/rectangle of the damaged area. Then I would make a rabbet cut on both the cabinet and the patch.

Rabbets2.jpg

This would give more surface area for the glue to adhere to both cabinet and patch, making a stronger patch.
Fill in the seams with bondo wood filler. Sand with 220 grit sand paper and figure out what to do with the artwork.
 
Depending on how far down the damage goes, I would go along the lines of what @DonPanetta said. I would probably make a jig to router out a perfect square/rectangle of the damaged area. Then I would make a rabbet cut on both the cabinet and the patch.

View attachment 641574

This would give more surface area for the glue to adhere to both cabinet and patch, making a stronger patch.
Fill in the seams with bondo wood filler. Sand with 220 grit sand paper and figure out what to do with the artwork.
This is how I would do it if it were mine. I think the jig wouldn't be needed though and over complicates the job. Just square up the damaged area and cut out the mess. Then cut a piece of particle board oversized a bit to use for patching. Set it inside the cabinet and trace the outline of the damaged area. You will then need to measure out a bit on the patch board to account for the rabbit on each side. Cut the patch board and with a router, rabbit all edges of the cabinet and patch board. Glue it in place and sand and filler as needed.
 
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