Window Sill and Frame Restoration

My prized stained glass window, exterior frame, was in rough shape.  While removing the paint I discovered two areas where large chunks of the frame had been filled with something that looked like plaster and it was not done well.  They were already loose, so I decided to remove them and search for a better product to use.  I was already familiar with wood epoxy, I used it to restore the inside frame, but I wasn’t sure if the product I used could be used outdoor.  I turned to Google and stumbled across several YouTube videos that talked about Abatron’s LiquidWood and WoodEpox.  I decided this was the product I wanted to use and with luck the Clifton Ace Hardware store carried the kit.  After watching Abatron’s video several times, I decided this was the product to use to also restore the window sills.

Since I wanted to finish installing the new plinths, I started with those sills first. As per the video I prepped the wood making sure all paint was removed and I used my vacuum cleaner to remove all dust and in the case of the bathroom window, suck out all the paint chips that had fallen in the huge cracks. I mixed equal parts of the LiquidWood parts A and B and applied it to the wood with a cheap bristle paint brush. The video suggest drilling 1/8″ holes in the wood to allow the product to seep deeper. I did this on the bedroom window sill since it was not as cracked as the bathroom window. That window sill felt brittle/frail to the touch. As you can see from the pics below the sill darkened after applying the LiquidWood.

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The video states you should apply the WoodEpox while the LiquidWood is still tacky, so after about 30 minutes I began mixing equal parts of WoodEpox A and B. The video suggests you can add LiquidWood to the WoodEpox to thin it out, if desired. I did not do this on my first use, but did for the remainder of the project as I felt the frosting like consistency was easier to apply with my putty knife.

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I let it dry a couple of days (I had things to do), but before installing the plinths I sanded them until smooth. First with 60 grit, then 120. They felt and looked stronger. This was definitely the right decision and right product, so I turned to the stained glass window next. It turned out awesome.

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The original kit I bought contained 12 oz LiquidWood and 12 oz WoodEpox. I got the plinth sills and the stain glass done with that kit. I ended up purchasing two additional, pint sizes (pint each of A and B, total four pints) of LiquidWood and one pint size of the WoodEpox to complete all the window sills and some minor repair on the rear portico. The process did not change, but I would suggest not working in extreme heat or direct sunlight. I repaired the dormer window sills from inside the house and was holding the cup of WoodEpox outside in direct sun. The product sets faster in heat, so I ended up wasting most of that batch as it hardened before I could spread it. With that lesson I also started mixing smaller batches as it only got hotter as this project went on.

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On a few of the windows the filler used to fill the notches that probably once held shutters were missing. The Abatron product is expensive and I didn’t want to buy any more WoodEpox, so to fill those areas I used a product called ScupltWood that I’ve had for months. I can’t even remember why I bought it, but it is also a two part epoxy putty like WoodEpox. I did apply LiquidWood to the area first in some instances, not all. The outcome was the same in both cases; that product worked great too.

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The windows and doors are now ready for paint. I’m ready to see paint. We are now heading into week five since Lyle’s Homes started (June 9) and he’s still scraping paint from the second floor. I can only hope that once he does start with paint that it goes twice as fast as prep because at this rate a Labor Day Drive By Open House is questionable. He’s still exceeding my expectations, but clearly his three week projection was misguided and it all can’t be blamed on the weather.