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Re: Wood in Hat Channels

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Posted by Don Prasse on November 27, 2002 at 18:41:36:

In Reply to: Posted by on November 20, 2002 at 11:48:53:

I dug as much of the old rotten wood out as I could. Then I welded the new hat channel in. I had a friend in the HVAC business simply bend some stock 16 GA sheet steel. In fact the legs were made wider to cover the rusted through streaks where the old channels had been.

Now the cool part. I mixed some epoxey and poured it down the ends and holes until I had filled as many of the channels as full as I could. This took several fillings. I would roll the tub in various attitudes to get the liquid epoxey to flow into all the nooks and crannies. As I would fill, the liquid would start to flow out a small hole or crack. A little duct tape would usually help contain things.

Hopefully it not only prevented crushing but also prevents corrosion inside the channels.

One problem was that I used some pretty old epoxey. Possibly 10 years old in cans that had been opened. Also it had a very long pot life and I may not have mixed it thoroughly. Some of the fillings took forever to harden which meant the process took days to accomplish, not hours. Also some of it has never hardened and still oozes. I am sure the method is sound. I just did not implement it well. Use an epoxey with a short pot life. It only takes a few seconds to dump it down the hole. Use fresh material and mix it well.


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