Join Date: Mar 2010
Location: La Crosse, Kansas
I've had to cut several hollow cores down; rentals, fixer uppers on no budget.... etc. The easiest way I've found is just cut it down to size and then resaw a piece of 2x4, 1-1/8" width usually works, and use that to plug it. Just glue it up and tap it in, a couple of brads for good measure. Same works to fix stripped out hinge screw holes where dowels and other means have been tried and failed. Just mortise out the area and stick in a hunk of 2x. May not be all that economical from a labor standpoint but it works.
If I strive for perfection, I can generally achieve good'nuff, If I strive for good'nuff, I generally achieve firewood