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These pockets of dry rot often can be repaired in place by excavating the damage and filling the cavity. 3.1 Excavate and fill Remove all wood noticeably damaged by rot, making sure to extend well away on both sides of the apparent damage. Use a chisel to excavate all of the weak, crumbly wood, leaving a clean cavity with solid wood exposed on all sides (Figure 3-1). Use a wire brush to remove any remaining soft wood around the cavity. The size of the exposed cavity will determine which of two filling methods is the most appropriate. You can fill small cavities with solid thickened wood plastic recycled composite flooringepoxy and fill larger cavities by bonding in a dutchman (wood shaped to fill the cavity).The decision to fill the cavity with solid epoxy or with wood is based on convenience, practicality and economics. You can save a lot of time if you can avoid carving intricate pieces of wood to fit hard to reach areas, but a solid epoxy patch weighs more and costs more per pound than wood. Also, you are limited by the epoxy's exothermic reaction to about a ?" layer (using 205 Fast Hardener?) in one application.
A larger volume would heat up enough to cause foaming and significant weakening of the epoxy. Although you may use slower hardener and/or apply the epoxy in multiple layers to avoid exotherm, there are practical limits to the size of cavity that can be filled with solid epoxy.Small cavities are most conveniently filled with solid thickened epoxy as follows: 1. Prepare the surface (Section 8.4.1). Be sure the area is thoroughly dry. 2. Wet out the repair area with the resin/hardener mixture (see Two-step bonding, page 65). 3. Fill the cavity with epoxy thickened with a high-density composite wall panel for a house(406,404 or 403) filler to a peanut butter consistency. Trowel the mixture into the void with a plastic spreader or mixing stick (Figure 3-2). Smooth the mixture flush with the surface and remove any excess before the mixture begins to cure. 4. Allow the mixture to cure thoroughly before sanding.Larger cavities should be filled with wood wherever possible. This method restores the original strength of the wood.
The procedure involves carving a dutchman to the shape of the void and bonding it in place with epoxy as follows: 1. Prepare the dutchman. Use the same kind of wood if possible. Carve the cavity to a geometric shape if necessary to make shaping the plug easier. Bevel the sides of the cavity. The longer the bevel on the sides running across the grain, the stronger the repair(Figure 3-3). An 8-to-1 bevel (8" long for every 1" deep) or greater will be close to the original strength of the wood. Check the dutchman for fit. Thickened epoxy will fill a fairly large gap,waterproof pvc wall covering south africa so the fit doesn't have to be perfect. Prepare the surfaces for bonding (Section 8.4.1). 2. Wet out the bonding surfaces of the cavity and the plug with resin/hardener mixture. 3. Apply thickened epoxy/adhesive filler (406, 404 or 403) (mayonnaise consistency) to the cavity surfaces. Using the mixing stick, apply enough of the thickened mixture to fill any gaps.
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