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Once you have removed the varnish, etc coat, and start sanding the actual wood, save the sawdust and you can mix it with glue ( PVA, epoxy, etc) to make a like-for-like filler.
However, it will depend on the final topcoats, as the top coat may show some differences due to differing levels of coat penetration and adherence.
Just leave it as it is - the rustic look is very popular.
Journeyman:Just leave it as it is - the rustic look is very popular.
The correct word to use is "distressed". So when someone points out that your door has had it, tell them it's a specialty distressed-look door that you got from an furniture restorer.
More seriously, you may be better off getting a new-old door from a demolition place and starting with that.
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