Step 4: Apply the Epoxy

Apply the Epoxy Save That Sash
Photo: David Carmack
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To rebuild the cleaned-out joints, first brush on the epoxy primer and let it set for about 20 minutes. Then, using a plastic scraper, mix the two parts of the epoxy filler into a goop the consistency of Vaseline. Force it into the joint, and spread the mix over the sides to restore the joint's original shape. Wait overnight, then trim the excess with a utility knife.

TOH Tip: Clamp pieces of Plexiglas over the wet epoxy. When it hardens, take the plastic off. You'll have a smooth surface that doesn't need much sanding.
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    Tools List

    • flat prybar
      Pry Bar
    • flathead screwdriver
      Flat-Head Screwdriver
    • electric heat gun
      Heat Gun (with nozzle shield)
    • utility knife
      Utility Knife
    • putty knife
      Putty Knife
    • dremel
      Dremel (with carving bit)
    • Natural Bristle Brush
      Natural Bristle Brush (for oil-based primer)
    • synthetic brush
      Synthetic Filament Brush (for top coat)

    Shopping List

    1. Flexible Epoxy Wood Repair System

    2. Plexiglas

    3. Glazing Compound

    4. Glazier's Points

    5. Oil-based Primer

    6. Acrylic Latex Paint

    7. Weatherstripping, if needed

    8. Silicon Spray

    9. Sash Cord or Chains