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15 Apr. 1990

Epoxy wood repair,making wood stain with vinegar and pennies,woodwork box project - How to DIY

Epoxy is the perfect material to make permanent repairs of rotting window sills, door jambs and exterior molding that are difficult to remove and expensive to replace.
In this article, we'll show you how to mix, apply and shape epoxy wood filler to create a long-lasting repair on damaged or rotted wood.
Once you learn a few tricks for mixing and applying the epoxy, you'll find it's as easy to use as Play-Doh. Probe the area surrounding the damaged wood with an awl or screwdriver to determine the extent of the rot. We're using a system of both liquid and putty-like epoxy made specifically for wood repair. Soft, easily penetrated wood is rotten or beginning to decay and should either be removed (Photo 2) or reinforced with epoxy consolidant as shown in Photo 3.


You mix it like cookie dough, mold it like modeling clay and, when it hardens, you carve and sand it just like wood. You'll need a hammer and chisel, a drill, and wood rasps and files, depending on your repair. It sticks like crazy and is formulated to flex and move with the wood, so it won't crack and fall out like some wood fillers. If a structural (weight bearing) member has been weakened by rot, you have to use other methods or in some cases special types of epoxy.
The brand we're using has a two-step system, which consists of two types of epoxy, a syrupy liquid consolidant and a putty-like wood paste filler.
The liquid consolidant soaks into the wood fibers and hardens to form a solid base for the wood filler.


As with any other epoxy, both the consolidant and wood filler consist of two parts, the resin (part A) and the hardener (part B). Mixing the two parts according to the manufacturer's instructions starts a chemical reaction that causes the epoxy to harden.


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