I have several rotted window sills that I would like to repair with an epoxy (Rot 3) instead of ripping out and replacing. In order to save on the cost of the epoxy, I am thinking about using Great Stuff expanding foam to fill the majority of the gap and then using the epoxy over the foam. The Great Stuff would quickly and comletely fill the holes (versus using scrap lumber filler). Any thoughts on this approach?
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If you do that you will just be postponing doing it right. It really isn't much more work or expense to just take out the old sills and cut some new ones and slide them in. Then with care they will last for many years. You can put foam under them to help hold them in place and to seal any cracks but I'd use minimal expanding type.