Drywall Repair Without Tape?! Try the Pumpkin-Cut Patch!

by Matt Weber

Ever since I learned about a new method to repair drywall, I have been interested in trying it out, just not interested enough to put a hole in a wall. Last month, someone else did that disservice for me, but repairing our dining room wall provided an opportunity to experiment with—and share with HIR readers—this handy technique dubbed “the pumpkin-cut patch.”

The pumpkin-cut patch stands out from other drywall repair techniques because it eliminates the need for joint tape, which normally prevents movement of the patch that can crack the joint compound. Using this alternative method, the movement of the patch is inhibited instead by the beveled edges of the patch interlocking with the beveled edges of the surrounding drywall.

The term “pumpkin-cut” is derived from the inwardly beveled edges that are supported by the opposing bevels around it—the same way the top of a jack-o’-lantern is cut with beveled edges so that it does not fall down inside the pumpkin. Eliminating the joint tape saves time, labor and materials, however, it helps to have an oscillating multi-tool (a.k.a. “buzz-cutter”) equipped with a plunge-cut blade to make the angled cuts and accomplish the job.

Here is how to make the repair, step by step:

Step 1

Measure the damage.

Step 2

Cut a square patch of drywall that measures a few inches larger than the damage on all sides.

Step 3

Use a pencil to trace the square patch around the drywall damage.

Step 4

Cut out the damaged area along the pencil line while holding the plunge blade at a 45-dgree inward angle.

Step 5

Clear away any loose drywall for a clean cutout.

Step 6

Cut 45-degree inward bevels along the edges of the drywall patch.

Step 7

A rasp or similar abrasive tool can help to shape the edges.

Step 8

Test-fit the drywall patch and adjust the fit along the edges by removing drywall as necessary with a mini hacksaw, keyhole saw, or even the blade (only) of a reciprocating saw. The patch should fit flush with or just below the surface of the surrounding drywall.

Step 9

Apply joint compound to the edges of the cutout.

Step 10

Apply joint compound to the edges of the patch.

Step 11

Place the patch into the cutout, using the compound like glue to adhere it into place.

Step 12

Apply a skim coat of compound to the edges of the repair.

Step 13

If necessary, use drywall screws partially inserted along the edges to hold the patch in place while the compound sets.

Step 14

After the compound dries, sand the area with a sanding block or damp drywall sponge.

Step 15

Finish the repair using standard drywall techniques, covering the patch with compound and feathering the edges of the coating thin.

Step 16

When dry, sand the patch as necessary to blend with the surrounding wall.

Step 17

Once the repair is completed and fully dry, apply primer and paint.

Step 18

The repair is complete.