Saving Rotten Wood Pieces

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Filling rotten area All the rot & bug problems should be taken care of now. Most of the rot has been removed and holes drilled into the wood for the Kwik Poly polyurethane to grab a hold even better. All the bugs have been cooked and are dead. You can see the wood is very dry after baking it, which is a must for the Kwik Poly to stick.

I've run 2" masking tape a long the outside of the wood to act as a form board to hold the Kwik Poly in during curing.

Pieces of Wood The first coat of Kwik Poly I just poured down all the holes and covered the old rotten area. Then I took saw dust from my belt sander bag and laid across the rotten area about 1/4" thick. Applied more Kwik Poly , then more saw dust, more Kwik Poly and kept repeating that process until I reached the height of the original edge.

Remember Kwik Poly hardens in about 5 minutes. Have all your items close by during this process to save time.

Close up of rotten part After about 30 minutes I sanded the Kwik Poly level with the original wood. Kwik Poly sands very easy and won't take long to get into shape. I then applied more kwik Poly and saw dust where needed and repeated the sanding process. I made sure to apply Kwik Poly all around the fixed area.

When all finished I sealed the wood with MiniWax Sandable Sealer. Next day I lightly sanded then and applied a low semi-gloss black.

Digging out Rotten Wood Here is the piece all repaired and in place looking very nice. All the wood around this piece is new oak or ash. Since so much of this piece was still good hard wood, and the cost of remaking this piece was so high, the repaired process we just went through is well worth it.

Remember not every piece of wood can be saved. Do a care review of any piece your thinking of saving, if it's not strong enough as is I'd really be looking at making a new piece. Last think you want is to be removing that piece after the total restoration is complete.