If the hole isnt too big a two part wood filler would be the easiest way, just fill it well let it go hard then sand down the excess. If the hole is too big for this you can try to chop a piece of timer in. Make the hole neater with a chisel or drill bit so you end up with a square, circle or similar regular shape. Apply Pva glue inside the hole, then get a piece of timber to wedge into the gap, make the timber like a pyramid small at one end but gets bigger so that when you hammer it in place it gets tighter and tighter untill it snuggly completely fills the gap(if you are feeling really clever try to cut the timber so that the grain will run the same way as the grain on the door), once u are satisfied that the hole is totally filled take off any excess timber still sticking out of the hole with a plane or chisel. Good luck.
Yorkshire Chippie, June 2008
