Old Home Living House One: Siding Repair With Epoxy

Editorial & Photography By: Dr. Christopher Cooper

Figure 1

The image in Figure 1 is usually the last nail in the proverbial coffin of older wood siding. A dryer vent, which is no longer in use has been filled-in with a very inappropriate expanding foam patch (which should never be used due to large amounts of moisture in its make-up). It is simply ugly and the average home-owner is not aware of high quality wood epoxies available on the market. Old Home Living’s Editor-in-Chief, Chris Cooper, has been using Restoration Grade Epoxy products for 22 years now on high-profile wood restoration projects around the globe, transforming rotted wooden elements which would be torn-out wholesale and bringing them back to life utilizing this high-tech product.

Figure 2

Chris will take us through the steps on how to restore the siding to better than new in minutes. Chris usually utilizes this product in conjunction with a liquid two-part epoxy however, in this case where there is no rot present, he will use Restoration Grade Epoxy (see fig.2). The foam was rebated using a utility knife, and a patch of tar-paper is stapled into place with stainless steel staples.

Figure 3

A very sharp chisel was then used to square-off the existing holes (see fig. 3). Because we are recycling board from the gable-ends of Old Home Living House we have exact patching materials, however, a piece of like material or poplar can be tapered with a belt-sander to fit (see fig. 4) the two pieces were then screwed into place with stainless steel screws (heads have been painted black for photographic contrast).

Figure 4

Figure 5

Two equal parts of A & B Restoration Grade Epoxy is kneaded by hand for 30 seconds to ensure a complete blending of the two-parts (use latex gloves it is rather sticky, see fig. 5). Chris has an interesting technique of applying the epoxy which has a pot-life of around 30-60 minutes. He first smears it into voids and cracks (see fig. 6), then pushes and palms the epoxy into place (see fig. 7) higher than the surrounding areas. Note: Restoration Grade Epoxy does not shrink, this just insures that all low spots have been filled.

Figure 6

Figure 7

After allowing the recommended time period for hardening (we waited overnight), Chris uses a random orbit palm sander to bring the epoxy flat, smooth and even with the surrounding clapboards (see fig. 8). Figure 9 shows the impressive results of this product which can now be sawn, nailed, planed, machined, stained, painted and finished as desired.

Figure 8

Figure 9

As with all exterior wood restoration a coat of Oil-based primer must be used (see fig. 10) and top-coated with two coats of 100% acrylic latex. Figure 11 shows the finished restored clapboards, we had to place a box around the area for you to see the repair, which in-itself is an excellent judge of the process.

Figure 10

Figure 11

In the past few months Old Home Living in conjunction with their production company 3Nine Productions Canada have been filming a DVD on the process of restoring rotted and damaged wood elements utilizing high-tech materials and traditional Dutchman techniques.

This DVD and other helpful restoration DVD’s will be released early next year world-wide, watch our web site and future issues of Old Home Living for availability.

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