It usually happens from the backsplash of rain dripping on your front step, it’s just that simple. Even though many people lean towards new composite type entry doors, I still stand behind the look and feel of an old fashioned wood door. Yes there’s maintenance, but no so much that I’d ever sacrifice the authenticity of it all.
Above is classic patch being performed by my father at a rotten corner of a four panel fir door. He’s made the proper cuts to start with a hand saw and just finished chiseling out the majority of the rot, but not to a point where he couldn’t insert a sufficient piece for the patch. (Make a note of using sharp chisels, not the ones at the bottom of the toolbox.)
He’s already got his piece prepared… but much thicker than the depth of his hole. He’s applying adhesive prior to inserting the cedar patch to ensure a nicer job.
Once the patch is installed, either a belt sander or electric planer can be used to bring the thicker patch down flush with the face of the door. It depends on the medium of wood you’re ultimately working with. In this case Sal used cedar, which is soft enough that the belt sander had no problem taking it down.
Don’t underestimate the process though, one wrong move and you’ll end up bringing your front door to the dump.
Just a couple photos below to show the process.
