"ameijers" wrote in message
...

"Kyle Boatright" wrote in message
...

"Robert11" wrote in message
...
Hello:

Have a wooden window sill that has a few inches x a few inches missing
from an outside corner.
Not rotted out, this area is totally gone. Probably rotted first, then
just broke off.

Hate to go to the expense of having a carpenter come in to replace the
whole sill.
Remember a few years back when we had one done, it was quite costly.

Was wondering if theres anything like "plastic wood" that would bond
very
well to the raw edge that was created, and that I can perhaps file or
grind to the right shape after it sets up.

It would have to have a "mass" that would cover perhaps 4" x 4" x the
thickness of the sill.
Quite a "chunk," I guess.

Any thoughts on this would be most appreciated.

Thanks,
B.

Believe it or not, Bondo (typically used in auto body repair) is
excellent
for this purpose. Follow the directions and apply several thin layers.
One
or two thick layers will crack due to the curing process...

Bondo is great for holes and soft spots, but lousy for sculpting shapes
out
of. If you make the 'ear' on a windowsill out of it, the first time
somebody
taps it with a rake, or leans on it, it will pop off.You need to
cut/chisel
away back to solid wood, and whittle a block to replace the missing stuff.
Glue'n'screw with deepset screws that you can putty or plug over. Make it
slightly oversize, so you can plane and sand it to a smooth transition.
(Covering this joint is what Bondo or epoxy are good for,) Most of the DIY
TV shows have shown this repair at least once- I expect that their
websites
probably have a step-by-step demo to follow. Other alternative is to saw
off
the front edge of windowsill, and add back a board. Ask This Old House had
a
segment demonstrating that. It helps if you have a similar window to copy
off of- otherwise you have to copy the other side of same window, and
'flip'
it all in your head. Don't forget the little groove on the bottom of the
sill- very important for controlling rain runoff.

aem sends....

You do have a point that unsupported bondo may chip. The way to overcome
that is to drive a couple of screws into good wood, but leave the head and
part of the shank sticking out. Then, you lay the bondo over the screws,
which provide structural support.

KB