How to Fix Rotted Wood with Epoxy | This Old House

This Old House general contractor Tom Silva saves a rotting window with a two-part epoxy filler. (See below or a shopping list and tools.)

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Tom showed Kevin how to repair a rotten windowsill and trim using a two-part "architectural" epoxy. The epoxy is designed to be flexible so that it will not separate from the wood as the wood expands and contracts with changes in humidity. Tom first grinded out the soft, decayed wood using a router. Next, he applied a bonding agent to ensure a good bond between the epoxy and the wood. Tom then traced the profile of the window trim onto a plastic putty knife and cut the knife to match the profile. Tom then dispensed the two-part epoxy using a special caulking gun onto the piece of plastic and mixed the two parts together. He then applied the epoxy to the windowsill and trim using his putty knives. Back in the loft, Tom recommended another application of epoxy for "touch up" and a light sanding before applying paint.

Shopping List for How to Fix Rotted Wood with Epoxy:
- two-part epoxy [https://amzn.to/2wG6uL9], used to rebuild rotted areas
- painter's tape [https://amzn.to/2MyRA44], for masking off area around the repair
- long, straight board, used as a straightedge [https://amzn.to/2WuO6V7]. Lexan panel [https://amzn.to/2QWpvCv], for use as an easel for mixing epoxy
- 100and 120-grit sandpaper [https://amzn.to/2K1tJbj], used to smooth hardened epoxy
- primer [https://amzn.to/2MApYf3] and paint [https://amzn.to/2IuReqd], used to finish the repair

Tools for How to Fix Rotted Wood with Epoxy:
- router [https://amzn.to/2Ip5Gjn] or cut-out tool fitted with a V-shaped bit [https://amzn.to/2MB2wyp], used to grind out rotted wood
- paint scraper [https://amzn.to/2Wsiakc], used for scraping off paint from wood surfaces
-plastic putty knives [https://amzn.to/2ItxmDw], used to apply epoxy
- aviation snips [https://amzn.to/2MyId4q], used for cutting profile of wood trim into plastic putty knife
- double-barrel caulking gun [https://amzn.to/2XzlgPJ], used to dispense two-part epoxy
- one-and-a-half inch paintbrush [https://amzn.to/2QWUJct]
- 1-inch-wide paintbrush [https://amzn.to/2Wp7wWm], used to apply bonding agent to wood
- 3-inch paintbrush [https://amzn.to/2wHO6BD], used to apply primer and paint

Two-part architectural epoxy for repairing rotten wood manufactured by Advanced Repair Technology, Inc. [http://www.advancedrepair.com/]

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How to Fix Rotted Wood with Epoxy | This Old House
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