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post #1 of 9 Old 09-25-2020, 12:04 PM Thread Starter
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Plywood Help

During the final stages of a project using Birch plywood, I found a soft soft on the face side of a project. After touching it feels like a void area under the top layer of the plywood. What is the best way to fill that void without doing a lot of damage to the face?
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post #2 of 9 Old 09-25-2020, 12:06 PM
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Kevin - what is the project and how will it be used ??

.

there is no educational alternative to having a front row seat in the School of Hard Knocks.
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post #3 of 9 Old 09-25-2020, 12:20 PM Thread Starter
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Cornhole project

This on the face, where cornhole bags will be landing on it.
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post #4 of 9 Old 09-25-2020, 03:08 PM
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leave it alone. any patching you do will stick out like a sore thumb
it is a corn hole board after all, it will eventually get some dings and dents to match that
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post #5 of 9 Old 09-25-2020, 03:56 PM
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Quote:
Originally Posted by KevinW View Post
During the final stages of a project using Birch plywood, I found a soft soft on the face side of a project. After touching it feels like a void area under the top layer of the plywood. What is the best way to fill that void without doing a lot of damage to the face?
Willing to bet it's Purebond brand plywood. There is a void there. They will veneer over a hole in the core veneer and you can't see it until you start finishing it and the veneer wrinkles. When I buy any of their plywood I tap my fingernails all over the sheet before building with it to see if there is any voids there.

Unfortunately there isn't a way to fix it without doing a lot of damage. You would have to take a sharp knife and cut the veneer off. Then fill the hole and cut a piece of birch veneer and inlay a boat patch. Would probably be easier to cut that part out of your project and put in a new piece.
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post #6 of 9 Old 09-25-2020, 05:55 PM
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Quote:
Originally Posted by KevinW View Post
During the final stages of a project using Birch plywood, I found a soft soft on the face side of a project. After touching it feels like a void area under the top layer of the plywood. What is the best way to fill that void without doing a lot of damage to the face?
I dealt with a similar problem this summer when I found a few soft spots on some old barn wood I was using on a table top. I ordered these bottles from amazon. Some of the needles that come with this kit are pretty small. I ended up using some very thin epoxy resin that I injected through a small hole to fill the void. After the epoxy dried I filled the hole that I inserted the needle into with colored CA glue.

The results weren't perfect but by the time I was done with the final sanding and finishing I don't think anyone would have noticed it except for me.

Plywood Help-dispensing-bottle.jpg

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post #7 of 9 Old 09-26-2020, 04:48 PM
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I like Bernie’s idea. I think a syringe like this would work too. I’d drill two small holes - one at the bottom to inject the epoxy into and one at the top to let air escape from and also to let you know that the void is full when you see epoxy coming out. Sand any blobs flush then apply your finish.
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post #8 of 9 Old 09-27-2020, 08:02 AM
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How about doing the fix from the underside? Plunge route from the underside. Fill the hole from the underside leaving the face ply in tact. The backside patch will be unseen.
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post #9 of 9 Old 09-27-2020, 08:47 AM
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I had the same problem recently with some maple veneer ply. Fortunately the project was painted so I just bored a shallow hole with a forstner bit and patched with a dutchman. Sanded it smooth and repajnted. You can't tell at all. If it's not going to be painted you might consider inlaying a bowtie or something in there. If it's going to sow might as well look classy...

A handful of patience is worth a bushel of brains...
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