One corner of this small triangular table had been broken off and needed to be repaired. The table top's substrate is plywood.

Equipment: Panel pins, plastic putty and powdered pigment or epoxy resin putty and a piece of veneer, piece of stiff cardboard, soap or wax, abrasive paper, files, chisels, paint brush; stain (optional).

The broken shape was rebuilt using a two-part plastic putty. When mixed together this has a slightly runny consistency that is good for moulding shapes.

Here's how
Form work was constructed to hold the mixture in place while the resin set. As an alternative to the plastic putty, you could use a two part epoxy resin putty. Using epoxy resin putty will save you the trouble of constructing form work.

1 If using plastic putty, snip the heads off two panel pins and insert them into the end of the corner for support. Tape a piece of stiff cardboard in the shape of the corner to the edges to prevent the putty spilling out. Smear soap or wax on the inside of the cardboard piece so that the cardboard will come away from the set putty easily.

2 Mix the amount of plastic putty required following the instructions supplied. Press the putty into place on the pins and mould it to the shape required. Mix some powdered pigment of a matching colour to the original surface with the plastic putty before adding the hardener. If using a two-part epoxy resin putty, mix an equal amount of each part together to form a stiff putty and simply mould it to the shape required. There is no need to add powered pigment to the epoxy resin putty as veneer is to be attached to it instead.

3 When the putty has set, reshape the corner to match the original using files, abrasive paper and chisels.

4 You can veneer over the hardened plastic putty or apply a wood stain. If using epoxy resin putty, place a piece of veneer that matches that of the rest of the table over the putty.

Slight damage
Minor damage to corners with a plywood substrate can be repaired by carefully separating the layers. Using abrasive paper, push a small amount of epoxy resin adhesive between the layers and cramp the corner.

Epoxy resin adhesive sets harder than other types of adhesive and will restore the integrity of the timber. Cover the repaired corner with veneer tape backed with adhesive.

Source:Repairing furniture (Murdoch Books)