How to Fix a Hole in Plywood Wall

How to Fix a Hole in Plywood Wall

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If the walls in your home are made out of plywood, then you definitely made a good choice, because it’s a relatively affordable and durable building material. With that being said, plywood can still break, and sometimes it does have holes in it.

The good thing about the material is that if it has holes in it, they are very easy to repair. Let’s get right to it and teach you exactly how to fix a hole in a plywood wall.

How to Fix a Hole in Plywood Wall

Although the process is fairly simple and straightforward, it does require the right tools and a good deal of precision. Therefore, we recommend following the steps below very closely in order to achieve the best results.

There are quite a few tools and materials required for this process, so gathering those is where this all starts.

Step 1: Gather Your Materials

As noted above, there are quite a few things that you will need to fix a hole in a plywood wall. First and foremost, you’re going to need more plywood, and yes, it needs to be the same type and thickness as the piece being repaired.

Ok, so you can use other types of plywood, but it might just look a little funny. However, the thickness is not negotiable. The piece being used to make the patch needs to be the same thickness as the piece being fixed.

Other than that, you will also need epoxy (that is designed for wood), a scraper or putty knife, sandpaper, a staple gun, paint, masking tape, a brush, a saw that can cut circular pieces out of plywood (such as a hole saw or coping saw), and a router or a sander.

Step 2: Measure the Hole and Prepare it

What you need to do first is to prepare the hole, to get it ready for the patch or plug. To do this, you want to sand or rout a 1/2-inch bevel that faces upwards along the edge of the hole in the plywood being fixed. This angled edge will help the plug or patch stay firmly in place.

Once you have done this, you want to measure everything as accurately as you can, because how well this all turns out will depend on how well your patch fits into that hole. What you also want to do before moving on to the next step is to use a brush to clear away any debris, sawdust, and anything else of the sort.

Step 3: Cut Out the Patches

Using your new piece of plywood that is of identical thickness and type with your piece being fixed, and using either a hole saw, coping saw, or even a jigsaw, cut out the patch of plywood according to the measurements you made in the previous step.

Remember to cut the patch as large as the hole is, including to the outer edge of the bevel you created in the previous step (as you will be cutting this bevel out of the patch).

With the patch cut out, you then want to take a router or sander and cut away a 1/2-inch downward-facing bevel or slope into the patch.

This way, you will have a downward-facing slope on the patch and an upward-facing slope on the edges of the hole, so when you go to join them, they will fit together like two puzzle pieces. Once again, brush everything off to ensure that there is no sawdust or other debris in the way.

Step 4: Apply Your Glue and Fill the Hole

In terms of the adhesive you use, you have two options here, which include wood glue and epoxy. In terms of waterproofing and structural integrity, epoxy is definitely the better option of the two. If using epoxy, now is the time to mix it, and be sure to work fast as it can set fast.

Use some masking tape to cover the area around the hole that you don’t want any epoxy getting on. Now take some epoxy and apply it around the edge of the hole, right on that upward-facing bevel.

With the epoxy applied, place the patch right into the hole and press it into place. Use any tool at your disposal to scrape away excess epoxy. You now need to let the epoxy cure and totally harden, which can take up to two days.

If you are worried about anything coming loose, use a staple gun to staple the patch into place (don’t staple too deep, because if you use staples, you will need to remove them before painting).

Step 5: Finish It Off

All you have to do now is to sand the surface down as you see fit, and then paint or seal it in any way that works for you.

Mistakes to Avoid, Tips & Tricks

The number one tip that we have for you to follow is to make sure that you cut those upward and downward bevels out of the piece being fixed and the patch. This is very important in order to ensure maximum structural integrity and adhesion.

Don’t leave the hole and the patch with perfectly straight and vertical edges. It just won’t work very well. Moreover, depending on the circumstance, you also want to make sure that the adhesive you use is waterproof, and that it has the ability to bond with wood.


The bottom line here is that fixing a hole in plywood is not very hard at all, and this is true whether it’s a wall or anything else. As long as you are precise with your measurements and your cuts, and as long as you use the right kind of adhesive, this should be a relatively easy task.