My carport has five 4x4 posts with two of them are showing serious signs of rot. I have attached a photo of the worst and 2nd worst looking one, and what the other ones look like. At first I thought the only way to repair the posts was to replace them. However some epoxy’s have incredible bonding stength, load bearing strength and water resistance properties. My plan to repair them with epoxy as follows:
- On each side of the post, cut the blacktop a couple inches away from the post, and expose the full length of the post.
- Remove as much rotting material from the posts as possible with a small chisel
- Liberally Spray a wood preservative solution of copper napthenate (green preservative) to halt the rot’s progression
- Prebuild forms that will be put around the posts once the resin mixture is ready, and spray them with silicone spray so they will come away from the resin a little easier.
- Mix West Systems 105 Resin with West Systems 206 Slow Hardener, and thicken the mixture with West Systems 403 Microfibers. Note, I may not necessarily use West Systems products, but something similar such as from conserve: http://conservepoxy.com/category/Rot-Repair-Epoxies.htm .
- Let the Resin cure for a day or so and remove the columns.
- Prime and Paint the posts, including the repaired area.
- Repair blacktop and raise the blacktop enough such that rain water will slope away from the posts. I got this idea from a blog here: http://www.westsystem.com/ss/saving-the-deck/
What do you think, is my plan sound?