How to Fix a Cracked Wooden Door or Busted Door Frame

As the elements take their toll on your home’s exterior, you may find yourself in need of a simple solution to fix a cracked or busted door frame or door.

In this post, we’ll discuss the materials you’ll need to repair the damage to exterior and interior doors, explain how to complete the repair and offer advice on how to make future wood door repair fast and easy.

Continue reading to learn how to fix a door.

Why Do Exterior Wood Doors Crack?

Exterior wood door panels crack due to a range of environmental and physical factors, such as natural swelling and shrinking of the wood in response to changes in humidity and temperature, poor staining or painting, and physical impacts like slamming the door.

To prevent a cracked door:

• Inspect wooden doors regularly for damage and make necessary repairs;
• Apply a high-quality oil-based sealant to the door’s exterior;
• Ensure hinges are tight and lubricated;
• Replace loose screws;
• Try to keep the door dry (wipe away excess moisture and condensation);
• Avoid slamming the door.

Tools & Materials

You will need the following tools and materials to repair exterior doors:

• Tools: Putty knife and a Dremel tool;
• Materials: Wood putty or filler, epoxy sealer, adhesive, wood spline, dust cloth, and sandpaper.

Preparing Your Work Area

Lay a towel or large clean rag near the door to protect your floor. This will provide a surface to put all your supplies so that you don’t have to worry about spilled wood putty getting stuck in the carpet or sticking to the floor.

Choosing Between Wood Putty and Filler

Wood putty is a pliable substance that is used to fill gaps and cracks in wood. It comes in a variety of different colors to match the wood and also helps to seal the wood and even out its grain.

Wood filler is a liquid product that’s formulated to fill large holes and cracks in wood. It’s typically made of plastic wood flour mixed with a solvent. It’s waterproof, hardens quickly, and provides a smooth surface after it dries. It can also be stained or painted over once it is dry.

The type of door crack filler you use for cracked door repair depends on the extent of the damage.

Step-by-Step Guide on How to Repair Split Wood Door and Door Frame

Follow these steps, and you’ll be able to repair your door’s cracked panels in no time:

#1. Apply Wood Filler to the Crack

If you are hoping for a permanent solution to a cracked door slab, or the damage is more than a small chip or nick, it is recommended to use wood filler instead of wood putty.

Wood filler does require some additional work, such as sanding and painting the door, but it will ultimately provide you with a longer-lasting solution.

To apply, either spread it onto the cracked part of the door. If you are using wood filler, it does not have to be applied perfectly because you will sand it down in the next step.

#2. Prepare for the Filler’s Dry Time

Remove any excess putty. It does not need to be level, as you will smooth it out later. Allow the putty to dry; high-quality putty takes less time to do so.

#3. Sand the Filled Surfaces

For a smooth finish, sand the surface where you applied the filler with gentle strokes, using medium-grit sandpaper (60-100 grit). Ensure the surface is even before finishing. For a longer-lasting fill, reapply the filler and let it dry before sanding again. Be careful when sanding, and take care not to scratch the paint or cause dents on the door.

#4. Repaint the Door

Once the door has been sanded, choose a paint with a similar tone. When painting, be sure to use the correct technique to avoid leaving brush strokes. If available, use a roller with a velour cover for a more finished appearance. However, if you’re painting the grooves of a paneled door, a paintbrush is probably a better choice. When finished, allow the painted door to dry before use.

#5. Use Epoxy Glue for Medium-Size Cracks

To ensure a long-lasting and strong repair, start by filling a medium-sized crack with epoxy sealer. Allow the sealer to fully dry before adding a bead of epoxy adhesive. Once the glue has dried, finish the job by coating the area with sealer and buffing the surface with fine sandpaper (grit 120-220). Finally, paint or stain as desired.

Fixing Large-Size Cracks

Some suggestions on how to repair a split wood door when epoxy or filler doesn’t suffice:

• Wood putty: Wood putty works like a paste to fill in holes and cracks in the wood. The benefit is that it is quite durable once dry. One potential issue is selecting the right color to match the wood, as wood putty is available in a range of colors;
• Wax sticks: If you have a long or deep crack that needs to be filled, using wax sticks can be a great solution. To use, press the wax stick into the crevice and mold it with your hands to fit the space. Once it’s in the right shape, carefully remove any excess wax using sandpaper or a putty knife. This results in a smooth surface;
• Wood glue and sawdust: You can try filling door cracks with leftover wood shavings, such as sawdust. You’ll need to experiment with this wooden door-fixing method and use your fingers to press the shavings in place and smooth them out.

How Much Does It Cost to Fix a Door?

The estimated cost for a broken wood door repair is typically between $100 and $500, but this can vary depending on the damage. Generally, the average cost to fix a chipped door is around $250 for repairs to the door’s frame – the low-end cost is about $50, while a higher-cost repair can cost up to $800 if there is severe water damage.

Replacing the Door: When Repairs Just Won’t Do

If you notice your door frame is warped, dented, scratched, or in poor condition, it may be best to replace the whole frame rather than attempt to fix the busted door frame.
However, if the damage is to the door slab and not the frame, these signs indicate it’s best to replace the entire door slab:

• The door drags along the floor and struggles to open;
• The door makes a noise when opened and closed;
• There’s a strong draft;
• Excessive light seeps through the door cracks;
• There’s visible rust and corrosion;
• There is termite and/or fungi damage to the door’s solid wood core.

If you are contemplating a door slab or frame replacement, consider how the new door and frame will have to be altered to match one another. Trying to install just one of the two without the other may prove more difficult than expected, so it’s recommended you hire a professional to replace your wood doors.

Upgrade Your Door With Apex Window Werks

If your wooden door is cracked or has a busted door frame, making repairs can be relatively simple. Depending on the size of the crack, you may need to use wood filler, epoxy glue, wood putty, or wax sticks.
In extreme cases, replacing the frame or door slab might be necessary. Apex Window Werks has upgraded many doors in Illinois, Wisconsin, and Minnesota. We have over 15 years of experience in wooden door fixing and know how to fix a cracked door. Contact us for a free consultation.