I am replacing a side porch. I have discovered some significant rot in parts of the sill. Is there a better way to resolve this without cutting out the sill. I’m thinking about boatbuilding epoxy…but would like to hear from someone who has tried this method.
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Chris,
That's something we learn to expect here in Maine. I don't have faith that epoxy and consolidants will work for structural elements, just for wood gutters, railings, window sills and sashes, etc.
Maybe someone else can clue us in to another product.
I've used West System for some cosmetic repairs and it may be fine for structural repairs, given the correct filler, ie micro balloons, cabosil etc. but given that you said 'significant' rot, I think it would be really expensive.
The other thing that boat builders especially say is that once the rot is there, it will only grow. Unless you remove the rotten wood, and the source/cause of the rot, ie leaks, touching ground, no amount of epoxy will get rid of it and it will continue to grow.
I would encourage you to re-examine removing the rotten sills.
Chris,
If the sill is not easy to remove and replace, I'd use borates to kill the rot and keep it from coming back (Wood Care Systems: 800-827-3480). Then I'd rebuild the sill using a structural epoxy (I prefer ConServ Structural Epoxy Repair 600 from Housecraft Associates; 201-579-1112). Both of those companies provide good technical support, so they should be able to help you work out the repair strategy.
Tom O'Brien