Restoring a Wooden Panel Door – Rebuilding and Refinishing

Article 38: Restoring a Wooden Panel Door – Rebuilding and Refinishing

By: A Woodworker Who Gives Old Doors New Life

Solid wood doors from the early 20th century are worth restoring. This guide explains how to fix loose joints, repair cracked panels, and refinish to a warm, lasting tone.

Materials

• Old panel door

• Wood glue

• Epoxy wood filler (if needed)

• Sandpaper (80, 150, 220)

• Stain or oil-based finish

• Tack cloth

Tools Needed

• Mallet

• Clamps

• Putty knife

• Orbital sander

• Flathead screwdriver

• Paint/finish scraper

Steps

1. Disassemble if Needed

   • Gently knock joints apart using a mallet and block. Remove old pins or pegs.

2. Clean and Inspect

   • Check tenons, panels, and stiles for rot or cracking. Replace sections if required.

3. Glue and Clamp

   • Reglue mortise-and-tenon joints. Use long clamps to square the door tightly.

4. Sand and Fill

   • Sand all surfaces flat. Fill cracks with wood filler. Wipe with tack cloth.

5. Apply Finish

   • Use stain or oil. Let dry between coats. Buff final coat for low sheen.

Sketch – Panel Door Cross Section

Top View:
  _________
 |         | ← Rail (horizontal)
 | [====]  | ← Panel inserted into groove
 |_________|
 |         | ← Stile (vertical)
 |_________|