Epoxy Filler

Epoxy filler is a high-performance, two-part adhesive compound used for structural repairs where incredible strength and durability are required. Unlike standard fillers, it's not just a cosmetic paste; it's a structural adhesive system.

It consists of two separate components:

1. Part A: An epoxy resin.
2. Part B: A co-reactant hardener.

When these two parts are mixed in their precise ratio, they begin an exothermic chemical reaction that causes them to cure into an exceptionally hard, solid plastic material. This resulting material is waterproof, resistant to chemicals, and has minimal shrinkage. It bonds with phenomenal strength to a wide range of materials, including wood, metal, concrete, and fibreglass, effectively becoming a permanent, structural part of the original substrate.

Using epoxy filler correctly is a straightforward process, but it requires careful attention to the preparation and mixing stages to ensure it achieves its maximum strength.

1. Surface Preparation: The surface must be completely clean, dry, and free of all grease, oil, and loose debris. For best results, sand the repair area with a coarse grit sandpaper (like P80) to create a rough texture, or "key," for the epoxy to grip onto tenaciously.

2. Mixing: This is the most critical step. Using a clean, non-porous mixing board and a putty knife, dispense the resin and hardener according to the exact ratio specified by the manufacturer (often 1:1). Mix the two components thoroughly for 2-3 minutes until you achieve a single, uniform colour with no streaks. Only mix an amount you can use within the product's "pot life" (the working time before it starts to harden).

3. Application: Apply the mixed filler firmly into the repair area, ensuring you press it into all corners and crevices to avoid air pockets. You can shape the filler as needed while it's still pliable. Leave the filler slightly "proud" (raised) of the surrounding surface.

4. Curing & Finishing: Allow the filler to cure for the time specified in the instructions. Once fully hardened, it can be treated just like the original material—it is strong enough to be sanded, drilled, tapped, and painted over.

While standard fillers are great for cosmetic fixes, you should choose a high-performance epoxy filler when the repair demands superior strength, waterproofing, or structural integrity.

Use epoxy filler for:

• Structural Wood Repairs: It is the number one choice for repairing rotted wood in window sills, door frames, or boats. After removing the soft, rotted material, epoxy filler will consolidate the wood fibres and rebuild the area with incredible strength.
• Waterproof Applications: Because it cures into a 100% waterproof solid, it is essential for any repairs below the waterline (marine use) or for exterior applications that are constantly exposed to weather.
• High-Stress Areas: Use it to repair concrete steps, anchor bolts into masonry, or fix cracks in fibreglass. Its immense bond strength ensures the repair will not fail under load.
• Rebuilding Missing Parts: Epoxy filler is strong enough to be shaped and sanded to reform missing corners on wood or to fill large holes where a structural fix is needed.

In short, if the repair is more than just a surface-level imperfection, an epoxy filler is the correct professional choice.