On Sep 28, 10:16*am, JP wrote:
I have been fighting a losing battle with a screen porch roof that is
made of aluminum panels butted against each other. Sealants on the
seams last about a year (18 months if lucky) before leaks start
again. *Each time I clean the old sealants off down to bare metal with
a wire brush. *I have tried the normal latex, silicon, polyvinyl etc
but they all fail. *The roof gets full Florida sun so it is UV
intensive and hot.

Any experts have a recommended product? *I have not yet tried an epoxy
based sealant fearing how hard it could be in the future to remove
it. *The panels are very tight together (no visible gaps) yet water
pours through in spots in heavy rains. *Is there a low-viscosity
product that will get between the panels and then expand?

Just wire brushing wont remove everything that can contaminate it and
ruin a bond, a strong solvent is needed like alcohol or laquer
thinner, Silicones have expiration dates, Ive had silicones not get
hard or not bind from using old stuff sitting on store shelves to
long. I would think a good fresh silicone would work,also temperature
of the roof and humidity will affect a bond.