How to Repair Rotten Wood

It is often easier to replace something when it has become tattered and worn, but Ron has always been a strong believer in bringing new life to something that's been around for awhile. To demonstrate how to repair damaged wood, Ron repaired a pair of shutters that had some pretty serious rot.

Click Here For a list of what you will need in order to complete this project.

1. Remove excess wood
When you have a damaged spot where some of the wood is still soft, remove as much of the crumbly stuff as possible without tearing too much of the wood out.

2. Consolidate wood
Next, apply a liquid wood hardener to the soft, damaged areas. This is called consolidating the wood. The wood hardener is a water-thin, epoxy-like product. When it is applied with a brush, it soaks into the wood, and turns the soft, partially decayed wood hard again. The consolidate dries in about two hours.

3. Create form for filler
Use small pieces of material like firm cardboard to build a form around the damaged area. First spray lubricant onto the back of the cardboard, which will allow the filler to release from the form when you remove it. Use duct tape to hold the form pieces firmly in place. The idea is to cover a couple of the sides of the void so that the filler can be packed into the rotten area without oozing out.

4. Filler
A poly-resin type filler is perfect for wood repair because it dries quickly and is extremely durable, especially when repairing something that will be used outdoors. This is an excellent material for doing home repairs; it is relatively inexpensive, easy to use, and dries very quickly.

A hardener is applied to the filler when you are ready to use it. The more hardener you add, the faster it will harden. Mix the hardener into the filler and start packing it into the void. As the filler dries, it becomes like dried chewing gum and becomes a bit rubbery.

After about ten minutes the material will become hard but still a little rubbery. This is exactly the consistency you want when you begin to clean up the excess. Remove the duct tape and cardboard forms. Then use a knife to cut away the excess.

After you have restored the general shape of the wood by cutting away the filler, sand the wood and filler smooth. The repair is now ready for priming and painting, which will make the damage virtually disappear.

5. Wood patch method
Another method of repair is to replace the rotten area with a piece of wood instead of filler. First, roughly measure the damaged area to create a wood patch that is slightly larger than the damaged area. After cutting out the patch, then trace the outline onto the shutter and then cut the damaged section away.

First use a handsaw and then a chisel to cut away the excess wood. Then glue the patch into place. Polyurethane glue is excellent for outdoor use.

A one handed face frame clamp is excellent for this type of project. It applies pressure on either side keeping the patch in place while at the same time, pushing the wedge down into the opening.

After the glue is dry, sand the edge of the patch off, flush with the surface of the shutter. All you have to do now is apply paint and blend it in.

Anyone can buy a new shutter, but they will miss out on the satisfaction that comes from restoring something old and bringing it back to life.