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I had the same problem and read about a simple solution. The cast iron and the latex caulk (water) are reacting (rust) and discoloring and breaking the seal. You can sand and clean, but once you add the water the process starts again. The simple solution was to paint the bottom edge where the sealant will touch with clear nail polish. It dries fast and quickly. Good luck.
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I have run into to a problem on a call-back. The cast iron vanity lav that was put in by my plumber using the water clean up caulk furnished with the lav deteriorated. I took up the lav and reset it using a water clean up caulk and it did the same thing. I think there maybe something that has contaminated the iron that is causing the caulk to break down.
Ant suggestions. Possibly I should silicone caulk. L.S.
*What brand caulk did you use? I've had virtually no problems with PolySeamSeal, but I suppose there's a first time for everything. What is the homeowner using as a cleaning agent around the lav? That could be the culprit, as well.
*I think the orginal in the box adhesive caulk that was in box with the lav was PolySeamSeal. Me thinks the contamination originated with my client and their house full of brats. I might take the lav up again and sand the cast iron on the bottom and then put it down with a 50 year silicone caulk. This really is bugging me. The caulk just turns to a snot like stuff. I cleaned it the last time real well and even cleaned it with lacquer thinner and made absolutly sure it was dry. Well I guess I will just do it again. I did a very major remodel there and I guess I owe them another try. L>S>
*You might consider a mineral spirit based caulk, like PL's or OSB's. Perhaps such a completely different formulation will help. I like Polyseamseal a lot, I'd be surprised if it's at fault. But then what do I know about cast iron? Was this a clear sealant? I think they are more fragile.Call the lav & caulk manufacturers before you do it again. And I've never been able to get really good results with silicone, maybe my ineptitude. I threw away all that I had, I disliked it so much.
*I had the same problem and read about a simple solution. The cast iron and the latex caulk (water) are reacting (rust) and discoloring and breaking the seal. You can sand and clean, but once you add the water the process starts again. The simple solution was to paint the bottom edge where the sealant will touch with clear nail polish. It dries fast and quickly. Good luck.
*Cool! Or prime the underside?