Wood Repair: How to Fix Damage From Rot

Filed under: fix-it, weekend projects, Tools, Patios, Porches & Decks, Know-How, Outdoors

When it comes to inexpensive wood repair, durable epoxy can fix rotted wood and save you hundreds of dollars in replacement costs.

Any piece of wood that traps moisture is highly susceptible to rot. Fences, decks, column bases, porch stairs, wooden planters, outdoor furniture, window casings and sills are all common locations for wood rot. Replacing decayed wood on a large scale is an expensive and time-consuming process, especially if you have to disassemble the structure. But if the rot is not too extensive, it can often be patched up with a mixture of wood flour (or sawdust) and two-part marine epoxy. Marine epoxy is a resin and hardener combo.

GETTING STARTED
To begin the restoration process, use a chisel or screwdriver to remove crumbling rot and debris from the area to be repaired. It is not necessary to remove semi-solid (or "punky") wood, as this can be treated.

After the rot has been removed, mix a suitable amount of epoxy per the manufacturer's directions. For safety, wear gloves when mixing and working with epoxy. Work outdoors if possible, or in a well-ventilated area.
APPLYING THE EPOXY
Many epoxies have two parts, resin and hardener, that must be mixed in a container just before application. When mixing epoxy, it is important to use the proper ratio of resin to hardener. Make sure not to mix more than what can be used in a few minutes. Epoxy hardens quickly, and once it does you won't be able to use it anymore. Tip: If you get epoxy on your skin, wash it immediately with vinegar, then use soap and water.

Once mixed, the epoxy will remain liquid for about 15 minutes. Quickly brush it onto the damaged area, soaking any places that are soft from the rot. Then stir wood flour, sawdust or a filler recommended by the epoxy manufacturer into the remaining epoxy until it reaches the consistency of peanut butter.

Fill gaps with the epoxy paste using a putty knife, or any tool that will allow you to shape the paste as required. If the gap is deeper than ¾ inch, fill it in with two or more applications of paste. Slightly overfill the final application and allow it to cure (but it will take a few days to fully harden).

SMOOTH AND FINISH SURFACE
After an hour or two, you can further shape the patch and remove excess filler with conventional tools, such as a utility knife, wood file or sandpaper.

Once the epoxy is cured (see left), it can be primed and painted to match adjacent surfaces.

While this is an inexpensive solution to wood rot, don't forget to identify and remedy the source of moisture that caused the rot in the first place. It's usually due to improper drainage, inadequate ventilation, poor construction techniques, or a combination of all three.

SEE ALSO:
Conceal a Nick in Wood Furniture
Wood Rot in Decks and Porches (Bob Vila)
The Wide World of Epoxy (This Old House)
How To: Put a Stop to Squeaky Floors (ShelterPop)

 

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