Expert: Stephen Major (Owner--Major Design Group) - 1/6/2012

Question
Stephen:
I replaced my kitchen cabinet hardware with new brushed nickel hinges and handles. The handles align OK, but the old holes for the new hinges are off by about 1/16 of an inch in many cases. I use bamboo skewer sticks to fill in the old holes, and attempt to drill a pilot hole 1/16 away from the old hole. Often times it works well, but often times the drill bit slips into the old hole. Is there any technique which you have found successful in addressing that problem.
I welcome any insight. Thanks for volunteering.

Answer
Nicholas,

You need to fill the hole in such a way that the filling is as hard or harder than the surrounding wood, and the hole is completely filled (no tiny gaps to catch the drill bit).  I typically overstuff the hole with a wood plug that is slightly oversized and (this is the crucial part) soak the hole and the plug with yellow glue.  Drive the plug in with a bit of excess wood and glue protruding, let dry until firm, then trim (with a sharp chisel) or sand flush.