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Tutorial: Filling Large Areas On Feet, Corners & Edges

In this Tutorial, Rod will show you a technique we use when we have to repair gouges or missing pieces in more difficult areas such as corners, edges and feet.

Follow these directions with the step-by-step photos , and you'll gain the confidence and know- how enough to tackle this project on your own. Filling larger areas in high wear areas can be tricky. Done incorrectly, the filler won't hold and pops out as soon as you go to sand it. Sound familiar ūüôā Not anymore....

shadow-ornament

We've all done it, right?  You fill a large gouge only to have the filler pop out and drop to the floor as soon as you begin togood grief sand it smooth.  There are a couple things to do when you find yourself in this situation.

Clean and sand the area to be filled

Fillers wont stick well in the presence of dust and dirt, so cleaning the area to be filled will go a long way in ensuring the filler sticks.  Also, if the area was exposed to chemical stripper, be sure all residue has been removed by using steel wool or a Scotch Brite pad and a solvent like lacquer thinner, alcohol or mineral spirits

On Larger Areas, Use Brads or Nails For Support

In the tutorial below, we have a large piece of wood missing on the foot of a cedar chest.

cedar chest broken foot 002

The technique we use here almost never fails and it's fairly simple.

Tools Needed:

1)  Hammer

2) Finishing Nails or Brads of the appropriate size in relation to the area being filled

3) Quick Wood Epoxy Stick  (or) Bondo (or)  Minwax High Performance Wood Filler

4) Sandpaper

5) Fix and Finish Touch Up Paint

cedar chest broken foot 003

Below: To Begin the repair, use one of your nails and carefully drive it into the area being filled deep enough so that the nail won't protrude after sanding.

cedar chest broken foot 004

Use as many nails as needed. Usually two to four is sufficient.  For this repair, I will use three.

cedar chest broken foot 006

Why The Nails?

The nails will now give our filler something to grip and bond to. This give our repair super strength. It's similar to using rebar in concrete.  Next Step. Below, I am using Quick Wood epoxy as my filler on this repair. I'm choosing Quick Wood because of the location on the foot. I need the strongest material at my disposal on a foot, and that is a Quick wood Epoxy Stick.  Feet and corners always get Quick Wood, while other areas I may opt for Bondo or Minwax high performance wood filler.

cedar chest broken foot 007

quick wood

When working with Quick Wood, I like to trim it and shape it before it hardens. Trim with a razor blade and smooth it out using water and your finger.  When using Bondo, trim with a razor blade within 5 minutes of applying.  Doing this will minimize sanding, as both materials will become harder than some species of wood.

  cedar chest broken foot 009

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Below: Using 120 sandpaper on the orbital sander, I sanded smooth.  I sanded the inside edge and bottom by hand, and with a detail sander.

cedar chest broken foot 012

That's about all there is to it. Follow all the steps outlined above and this repair method will almost never fail.

Finishing Note:

None of the fillers mentioned in this tutorial accept stain.  When refinishing, just stain and finish as you would normally, and at the end, touch up the repair using Fix & Finish Touch Up Paint. It's the best product for touching up this type of repair!

fix and finish add

 HAPPY  FINISHING!