Yikes! Easiest way to fix this hole?

cmjb13

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I don't want to try Bondo as I'm not looking for perfection or a drawn out repair

Maybe a black speaker grille or piece of sheet metal bended and painted?
 

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The most common resolutions are leave the hole and screw the door in from other areas, or replace the whole door. I don't think it's possible to repair particle board like that. Or cut and graft in new wood as others suggested.
 
Screwing the door in: lame operator hack. 😞
Super easy to fix with a small piece whittled down to near the size of the hole. Glue in place and fill the rest of the voids with saw dust and wood glue mixed to oatmeal consistency. Sand, paint, done!
And it's a back door so you can do a bad job and no one will care. Great way to practice and advance skills.
Get good enough at it you can make an unpainted part look like original wood .
 
I'd cut the replacement piece, then use it to scribe my cut lines on the door. Stay inside that line when you cut and you should have a good fit … might even need to file/sand the cut hole a touch larger. Gorilla glue will get the job done even on particle board.


This is the way.
 
If you've ever seen the back of a 90s Midway cabinet, that could give you some inspiration to get it done fast without wood working.
 
The fastest way for me would be to cut the hole to have straight lines, in this case a nice sharp "V". It's difficult and unnecessary to glue to jagged edges.

Then I'd cut a piece to fit that V and glue it in.

Sand, paint.
 
Measure the maximum height and width.
Cut a replacement piece that size.
As noted above, put the replacement piece down, and scribe around it.

You want bonus woodworking? Cut an inside 45 degree angle for your damaged piece on two sides, and cut the opposite angle on the replacement piece, then glue it into place. Sand and paint - done.
 
You have 95% of a door. That's more than many games. Ignore it and push it against the wall
 
This was indeed a door to a Sente Sac 1b, though the sticker inside says 1a

I decided to go the Bondo route with bar clamps and wood, though before I saw the last post with a similar recommendation. I didn't use wax paper, though it's a good tip for future reference.

Not perfect, but way better than it was. I'm going to leave the off center lock hole where it is.
 

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