How to Fill Gaps in Plywood: A Step-by-Step Guide

Plywood is a popular material for many projects, but there are some drawbacks to using it. One of the most common problems that people have with plywood is gaps between boards. These gaps can be unsightly and difficult to deal with. Luckily, there are ways you can fill these gaps if they ever arise. In this article, we will show you how to fill gaps in plywood step-by-step.

First sand the surface down so that the wood filler will adhere properly. Once the surface is sanded, apply the wood filler according to the instructions. After the filler has dried, sand the surface again so that it is smooth. If there are still gaps remaining, try using caulk to fill them in. Once the surface is smooth, your project is ready to be enjoyed.

What Causes Plywood to Have Gaps?

The main reason for gaps in plywood is that it’s made of multiple layers. When you put the pieces together, there may be slight bumps or spaces between them that can’t be filled with anything else since they’re internal to the structure.

The two most common reasons for this are wood expansion and moisture absorption. Wood can expand and contract with humidity levels. This means that the wood is going to grow larger when it’s been exposed to water, which can lead to a gap between pieces of plywood if left untreated.

Moisture absorption is another common cause of gaps in plywood. If there has been any kind of moisture damage on your project, then the wood is going to swell and leave a gap between pieces of plywood.

How Can You Fill the Gaps?

  1. Fortunately, there are plenty of ways you can fill gaps in plywood. The most common option for filling these gaps is putty. Putties come in different colors based on their composition, including white putty, drywall putty, and wood putty.
  2. Another option for filling gaps in plywood is to use a caulking gun or paintbrush. You can also opt to fill the holes with a piece of dowel rod that’s been cut down to size. If you don’t have any dowels around, then you can just as easily use toothpicks.
  3. If the gap is small, then you may be able to just cover it up with some paint.
  4. You could also take a piece of sandpaper and sand down the edges that are sticking out if they’re very noticeable or prominent enough.
  5. The last thing you can do to fill gaps in plywood is drill out the hole. If there are any screws stuck in place, then this could be a great option for filling spaces between boards.

[Also read How to fix warped plywood]

Tools Needed To Fill In Plywood Gaps

Putty Knife Scrapers, Spackle Knife, Metal Scraper Tool for Drywall Finishing, Plaster Scraping, Decals, and Wallpaper (4 Pack, 5”, 4”, 3”, 1.5” Wide)
Sandpaper Sheets, 42 Pcs Sand Paper Assortment Pack, 120 to 3000 Grit Wet Dry Fine Sandpaper Assortment, Variety Abrasive Sanding Paper with Handle for Metal Wood Furniture Automotive Car Polishing
TOLESA Anti-Drip Hand Caulking Gun High Thrust Ratio 12:1 with No Dripping Control for Kitchen Bathroom Window Easy Caulk Gun Non Drip 10oz (310ml) Silicone Caulking Tools Kit with Caulk Removal Tool
DEWALT 20V MAX Hammer Drill and Impact Driver, Cordless Power Tool Combo Kit with 2 Batteries and Charger (DCK299M2)
Dowel Rods Wood Sticks Wooden Dowel Rods - 1/2 x 36 Inch Unfinished Hardwood Sticks - for Crafts and DIYers - 10 Pieces by Woodpeckers
Water-Based Wood & Grain Filler (Trowel Ready) - Neutral/Base - 1 Gallon By Goodfilla | Replace Every Filler & Putty | Repairs, Finishes & Patches | Paintable, Stainable, Sandable & Quick Drying
Putty Knife Scrapers, Spackle Knife, Metal Scraper Tool for Drywall Finishing, Plaster Scraping, Decals, and Wallpaper (4 Pack, 5”, 4”, 3”, 1.5” Wide)
Sandpaper Sheets, 42 Pcs Sand Paper Assortment Pack, 120 to 3000 Grit Wet Dry Fine Sandpaper Assortment, Variety Abrasive Sanding Paper with Handle for Metal Wood Furniture Automotive Car Polishing
TOLESA Anti-Drip Hand Caulking Gun High Thrust Ratio 12:1 with No Dripping Control for Kitchen Bathroom Window Easy Caulk Gun Non Drip 10oz (310ml) Silicone Caulking Tools Kit with Caulk Removal Tool
DEWALT 20V MAX Hammer Drill and Impact Driver, Cordless Power Tool Combo Kit with 2 Batteries and Charger (DCK299M2)
Dowel Rods Wood Sticks Wooden Dowel Rods - 1/2 x 36 Inch Unfinished Hardwood Sticks - for Crafts and DIYers - 10 Pieces by Woodpeckers
Water-Based Wood & Grain Filler (Trowel Ready) - Neutral/Base - 1 Gallon By Goodfilla | Replace Every Filler & Putty | Repairs, Finishes & Patches | Paintable, Stainable, Sandable & Quick Drying
$9.99
$14.99
$24.99
$389.00
$21.33
$54.99
Putty Knife Scrapers, Spackle Knife, Metal Scraper Tool for Drywall Finishing, Plaster Scraping, Decals, and Wallpaper (4 Pack, 5”, 4”, 3”, 1.5” Wide)
Putty Knife Scrapers, Spackle Knife, Metal Scraper Tool for Drywall Finishing, Plaster Scraping, Decals, and Wallpaper (4 Pack, 5”, 4”, 3”, 1.5” Wide)
$9.99
Sandpaper Sheets, 42 Pcs Sand Paper Assortment Pack, 120 to 3000 Grit Wet Dry Fine Sandpaper Assortment, Variety Abrasive Sanding Paper with Handle for Metal Wood Furniture Automotive Car Polishing
Sandpaper Sheets, 42 Pcs Sand Paper Assortment Pack, 120 to 3000 Grit Wet Dry Fine Sandpaper Assortment, Variety Abrasive Sanding Paper with Handle for Metal Wood Furniture Automotive Car Polishing
$14.99
TOLESA Anti-Drip Hand Caulking Gun High Thrust Ratio 12:1 with No Dripping Control for Kitchen Bathroom Window Easy Caulk Gun Non Drip 10oz (310ml) Silicone Caulking Tools Kit with Caulk Removal Tool
TOLESA Anti-Drip Hand Caulking Gun High Thrust Ratio 12:1 with No Dripping Control for Kitchen Bathroom Window Easy Caulk Gun Non Drip 10oz (310ml) Silicone Caulking Tools Kit with Caulk Removal Tool
$24.99
DEWALT 20V MAX Hammer Drill and Impact Driver, Cordless Power Tool Combo Kit with 2 Batteries and Charger (DCK299M2)
DEWALT 20V MAX Hammer Drill and Impact Driver, Cordless Power Tool Combo Kit with 2 Batteries and Charger (DCK299M2)
$389.00
Dowel Rods Wood Sticks Wooden Dowel Rods - 1/2 x 36 Inch Unfinished Hardwood Sticks - for Crafts and DIYers - 10 Pieces by Woodpeckers
Dowel Rods Wood Sticks Wooden Dowel Rods - 1/2 x 36 Inch Unfinished Hardwood Sticks - for Crafts and DIYers - 10 Pieces by Woodpeckers
$21.33
Water-Based Wood & Grain Filler (Trowel Ready) - Neutral/Base - 1 Gallon By Goodfilla | Replace Every Filler & Putty | Repairs, Finishes & Patches | Paintable, Stainable, Sandable & Quick Drying
Water-Based Wood & Grain Filler (Trowel Ready) - Neutral/Base - 1 Gallon By Goodfilla | Replace Every Filler & Putty | Repairs, Finishes & Patches | Paintable, Stainable, Sandable & Quick Drying
$54.99

1. Putty Knife

A putty knife is a great tool for filling in gaps between boards and smoothing out the material. It’s similar to an icing spatula or butter knife, but it has more of a sculpting edge on one side of the blade. This will allow you to fill holes with materials like wood glue better than if you used a butter knife or icing spatula.

A putty knife can be used for exterior and interior plywood projects, making it an incredibly versatile tool that’s well worth the money if you’re working with any kind of wood at home.

It also has a plastic handle which makes it very easy to grip when you’re using it to fill in any kind of gap.

2. Sandpaper

Sandpaper is another useful tool to fill in gaps between boards. You’ll want sandpaper that’s at least 200-grit for this task, but ideally, something around 220 or 280 would be best.

The next step after filling the gap with your material of choice will be using some form of sanding device to level out the surface of your plywood.

Many people recommend using an orbital sander for small jobs like this since it’s simple to grip and manage while smoothing down any ridges or uneven spots on your project.

3. Caulking Gun

A caulk gun is a great tool for filling gaps in plywood. It works by pulling back on the handle and pushing it forward to release a bead of caulk that can be used for filling in any gaps or holes you have on your plywood project.

Caulking guns come in various sizes and colors, making it easy to find one that’s going to match your project.

4. Drill

If you find that there are any screws sticking out on your project, then using a drill to fill in the gaps is another excellent option.

Just make sure that you drill down far enough to reach the plywood. This will help ensure your screw is flush with the surface of your project.

5. Dowel Rod

A dowel rod is a great option for filling in gaps between boards on your plywood project. It’s typically a long wooden stick that has been cut down to size so it’s the same width as the gap you’re trying to fill.

  • To get started, just take your dowel rod and place it into the hole until it reaches all of the ways through from the top to the bottom.
  • Depending on what material you use, it may be necessary to drill a small hole in your dowel rod so that it fits properly into the hole you’re filling.
  • Once your dowel rod is in place, use a mallet to drive it down as far as possible to ensure it reaches the bottom of your plywood board.
  • You can then take some wood glue and spread that onto the dowel rod to fill in the rest of the gap.
  • Once you’ve gotten as much glue on there as possible, take a few clamps and secure your dowel rod into place.
  • Let the glue dry for at least a few hours before you move on to your next step of smoothing down your plywood board.

6. Wood Filler

Wood filler is a great option for filling in gaps on your plywood project. This will create an even surface over the entire board, which is important if you’re looking to smooth over any visible imperfections that might be left behind.

There are many different brands of wood filler, so it’s important to choose one that meshes well with the type of plywood you’re using and what your project entails.

Once your wood filler has dried, it will be time to start sanding.

How to Fill Gaps in Plywood

How To Fill In The Gaps: Step-by-Step Instructions:

Here are 10 steps to follow when filling gaps in Plywood with wood filler.

  • Step 1-The first thing you’ll need to do is prepare the area where you’re going to be working. This means getting rid of any excess items around your project or covering up anything that might get in the way during this process, like furniture legs, and pets. It’s also a good idea to cover your floor with an old blanket just in case any excess filler goes flying during this process.
  • Step 2-After you’ve protected the area where you are working, it’s time to get started with filling in gaps on your plywood project. To do this, make sure you have all of the tools mentioned above before getting started. This includes a drill or dowel rod for making holes, a caulking gun for filling in gaps with caulk, and wood filler.
  • Step 3-Now that you have all of your supplies ready to go it’s time to fill in any gaps on your plywood project. If there are screws sticking out from the surface of your board, then using a drill is going to be your best bet to fill in any gaps. To do this, just drill down into the plywood board until it reaches all of the ways from top to bottom.
  • Step 4-Once you’ve made a hole with your drill, it’s time to fill in the gap. To do this, take some wood filler and scoop out a small amount onto an old credit card or another thin piece of plastic so that you can use it as your spreading tool. Make sure not to add too much since it will be very difficult to spread evenly otherwise.
  • Step 5-Now that you’ve scooped out some wood filler, it’s time to use it on your project. Take the credit card or plastic tool and push it into the hole until all of the excesses have gone through to fill in any gaps between boards on your plywood project.
  • Step 6-Once you have the wood filler in place, it’s time to smooth out your new surface. To do this properly, simply take a damp cloth and wipe off any excess that might be on top of the board so that everything is evened out. You can then use sandpaper or another type of rough material to smooth out the surface even more so that it’s completely flush with your plywood board.
  • Step 7-Now you can move on to filling in any gaps with caulk if necessary or continue with whatever project you’ve been working on up until this point. You will most likely have to wait for a few hours before the wood filler has dried enough to move on, so make sure you prepare for that in advance.
  • Step 8-Once the wood filler is dry and your project surface is completely smooth it’s time to get started with sanding. To do this properly, simply take a damp cloth and wipe off any excess dust before getting started. You can then use low-grit sandpaper to smooth out the surface even more so that it’s completely flush with your plywood board.
  • Step 9-Now you’re ready to move on and continue working on the project as normal, or apply any paint or stain if necessary. Even though wood filler isn’t known for leaving a smooth finish on its own, once you’ve applied paint or stain you should be left with something that looks completely different than before.
  • Step 10-Now that your project is done and all gaps have been filled in properly it’s time to enjoy the finished look of your work.

Precautions

When you’re working with a large piece of plywood, it’s important to take precautions to avoid injuries. Here are a few tips to keep in mind:

  • Wear gloves when handling the plywood to avoid splinters.
  • Use a saw horse or other support to hold the plywood steady while you work.
  • Be careful when using power tools, and always follow the manufacturer’s instructions.
  • If you’re working with a large piece of plywood, it’s important to take precautions to avoid injuries. Here are a few tips to keep in mind:
  • Wear gloves when handling the plywood to avoid splinters.
  • Use a saw horses

Expert Tips on How to Fill Gaps in Plywood

Plywood is a great material to use for a wide variety of projects. However, one thing that can be frustrating about plywood is trying to fill in gaps between boards. If you’re working on a project and have gaps that need to be filled, then follow these steps and you’ll be able to get the job done quickly and easily.

FAQs

Q: Can I use wood filler on any type of plywood?

A: Yes, the wood filler can be used on any type of plywood as long as it’s sanded down properly beforehand.

Q: What happens if I don’t sand the surface before using wood filler?

A: If you don’t sand the surface before using wood filler, it’s likely that the filler won’t adhere to the plywood properly and could cause your project to fail.

Q: Can I use any type of sandpaper on my plywood project?

A: Yes, you can use any type of sandpaper on your plywood project as long as it’s low-grit sandpaper. This will help to ensure that the surface is completely smooth before you move on.

Q: How long should I wait for the wood filler to dry before moving on?

A: It’s typically best to wait for a few hours before moving on so that the wood filler has plenty of time to dry properly. This will help to ensure that your project turns out the way that you want it to.

Q: What should I do if there are still gaps after using wood filler?

A: If there are still gaps after using wood filler, then you can try using caulk to fill in any remaining spaces. This should help to create a smooth surface that’s ready for sanding.

Q: What should I do if the wood filler isn’t drying properly?

A: If the wood filler isn’t drying properly, then you can try using a hair dryer to help speed up the process. Simply hold the hair dryer close to the area where the filler is and wait.

Conclusion

This blog post has provided a step-by-step guide on how to fill gaps in plywood. Follow these steps and you will have a finished project that looks great.

Also read How to fix warped plywood

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