Any thoughts on how I can fix this?

Make a wider rabbet.

Cut a wider rabbet or chop it out square with a chisel and implant another piece of wood. Fill the cracks with glue and sawdust to hold it in.

-- Improvise.... Adapt...... Overcome!

If this is the bottom of the frame, I think I would square it off, cut an inlay piece from the same wood, glue and clamp it, then sand & finish.

-- HorizontalMike -- "Woodpeckers understand..."

I was typing while Dallas was typing the same response 8-)

-- HorizontalMike -- "Woodpeckers understand..."

Mark, been there before as well. For that I would not use filler. I would square up the divot and glue in place a small piece trying to match the grain pattern as much as possible, but being that small you dont need it to be perfect. Being on the back of the door it will not be that noticeable once finished. Hope that helps. Enjoy!

-- Troy, Virginia

Is this a stain or paint grade project?

If paint grade or if you’re not terribly concerned about the repair showing, I’d use something like Durham’s Rock Putty. It comes as a powder and dries hard as a, well, rock. You can use your router to rework the rabbet afterwards.

-- Friends don't let friends use right tilt contractor saws......

+1 to both replies. I have done this before :( I have used the Dallas technique, of squaring it off and gluing back in. I Have gone with a bigger piece and then re routed flush. for easier sanding, and the satisfaction of getting to do it right the second time. If this is paint grade, may I recommend BONDO body filler, with the red activator. I have even filled gouges about like that, let them cure and re routed them.

-- Who is John Galt?

Ha!!! Jinx to all…. all owe me a pop!

-- Who is John Galt?

I like the “make the rabitt wider” idea, but you could try cutting a piece to match the gouge, glue and sand it. If it doesn’t work your now worse off than you are now.

-- There is nothing like the sound of a well tuned hand plane. - http://timetestedtools.wordpress.com (timetestedtools at hotmail dot c0m)

Damn, you guys are fast! I like the squaring off idea thanks gents.

Joey. WTF?!

-- Mark

What are you doing in my shop taking pictures of all my wood?

A wooden patch or wider rabbet is your best approach, IMO.

-- jay, www.allaboutastro.com

Or, use a contrasting wood grain and make it look custom.

Walnut comes to mind, if it’s stain grade.

I wouldn’t square it at all. I would just get another piece of this same wood and hand carve a sliver to fit in there and glue and sand flush.

-- Bondo Gaposis

Sorry…. Jinx is what we would call when two or more people say something at the same time. The first person to call it got a soda. It seemed like 5 people wrote the same thing at the same time. When I posted my reply. So I thought I would call jinx. Just thought it was funny. that is all. sorry to be confusing.

-- Who is John Galt?

scrap it and start again you lazy ass lol how are you bud long time no talk

-- cut it saw it scrap it SKPE: ANDREW.CARTER69