Saturday 16 June 2012

How to repair rotten window cills with epoxy and micro balloons

Not just window cills but door frames with  cills as well. Given a homes Meranti frames were at least coated with some thin varnish prior to being built into the brickwork, we should see about 25 years service, just where you live will extend or reduce the service life.


After the initial raking out and cleaning, plus 24 hours to allow the damage to dry out, the repair was fixed in no more than an hours work.



The underside of the meranti window cill has developed rot for the full length of the frame, it can be repaired using a system I developed using our epoxies.



The system works and has prooven itself many times, we supply you with self repair kit of epoxy and fillers. You may require the skills of a carpenter on some jobs.


Using our AR 600 epoxy, I mixed a batch of just over 260 grams. the ratio is simple, 100 grams of epoxy to 30 grams of hardener, any small scales will work for this.


I then mixed the two components and applied with a brush to the affected area, this is working as a primer at this stage.


I next added the 3M micro balloons and fumed silica in more or less equal amounts to make a thick paste.



The mix when applied to the opening under the wooden cill, I used a mixing stick and a spatula to do this. This is quite a messy job, its important to push as much of the white mix into the space left by the rot of the wood. Clean up well, you really do not want to be sanding the white epoxy filler mix down when its gone hard.


Application was easier when the window would open.


I could have left the epoxy filler mix as the final pre painted finish but decided the job would look better with a small wood trim, note the white filler return up the side wall, the wood frame behind looked soft, best to cover it now.


The wood trim held itself in place, note the small wood wedge on the left hand side, that held the wood trim down to the cement white painted cill, there are no fastenings in the wood trim at all.


A simple fixing method, a small wedge made from a scrap of wood.


The finished job before painting, epoxy needs a cover coat of paint as the UV rays will eventually break epoxy down. How easy was this? well given some epoxy and fillers, the wood trim and very few tools I took no more than one hour and I used only a small hand saw to cut the wood trim to length, plus some scraper tools.


Epoxy repaired just yesterday, one coat of Plascon paint on today, next are the white PVA painted reveals, not sure quite when its started to rain but at least we know no water will enter the house through the damaged cill now.

How easy was that!

Some say we can also build boats from the same materials? Epoxies and fillers are available in a carton by post or collection.

A regular blog viewer has asked what the difference may be with using a Carpenter to remove the old cill and refit a new one ? The method will require taking both the opening and fixed sash right out, plus the central bar. The cut and chop out of the old cill, then to refit a new one plus the sash replacements should take about six hours?

Rates per hour right now are around R360, so thats R2160 plus R100 for the new Meranti cill, thats now an invoice to you of R2260 and you still have to repaint it. A 1.3 litre pack of AR600 epoxy and filler powders will cost you R257, OK you may still need a Carpenter for one hour but you can see this sort of method of repair still makes a lot of sense.

www.ckdboats.com 

Roy