I've done the first pass at patching and sanding the casing boards, a major step in the restoration process that I discussed in detail when I restored the casing boards on the north dormer. It occurred to me that a brief video showing the results of the first pass this time might be effective in clarifying some of the details of the work that were left unclear the first time.
I've been planning since I started this blog to use video from time to time to illustrate processes, but I learned early on that making a decent video is harder than it seems. Thus, while I've made dozens of video presentations for you, most of them have stunk for one reason or another.
I think I've come far enough along the learning curve now to start using this method more often, and so, here you are. I'm afraid that I left a few details out of my narration, however, so let me add them now.
Patching to this extent is a complicated process requiring several passes, and with this first pass my intent was to fill in the major voids and irregularities on the front of the boards, including the re-building of the edges. While I subsequently sanded the sides back all the way, the fronts I only sanded far enough to remove the rough edges and ridges and begin to establish a flat surface.
I left the putty somewhat above the eventual plane of the finished board so that there would be enough depth in the remaining voids to allow the putty to take hold in them. If a void is too shallow, the friction of the putty knife will pull the epoxy right back out as it passes over, and if I pass the putty knife too high, all I will do is replace the divots with bumps that will be a pain to sand back down. By sanding high with this first pass, I will be able to fill in more of the small divots successfully, and then sand the entire surface down at the same time to the proper level.
One more thing I forgot to mention: while I previously discussed my intention to use Bondo for this first pass, I subsequently decided against it. While I did use it successfully on our Culver City home, and the work has held up for over 15 years, that was in an area with little exposure to the sun. I don't know how it would hold up in full sun in the harsher Pasadena environment, nor do I know how well it would get along with the WoodEpox I would have used for subsequent passes. Given the prominent position high in the front of the house, I didn't want to risk the failure of the patch down the road, and the virtual impossibility of effecting a permanent fix if it did.
Now, without further blather, here's the video.