What to do when THRU-BOLTING won't do ...

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DaleH

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FYI:

One of our esteemed members had a problem where they wanted to through-bolt an item to their deck, but they can't get to the underside nor is there room enough to use a Toggler or other 'in-hole' mechanical fastener.

So, here's a GREAT and simple DIY idea for if/when you 'have' to and are forced :shock: to use regular wood screws. In a word ...epoxy!

First drill the hole where needed, but oversize, in fact at least 3-4X times the size of the body diameter of the screw you will use. Now the trick is to somehow EXPAND the bottom of the hole so it is much larger than the top. I have used rotary bits on drills or Dremels tools, chisels with a small rounded tip (called a gouge I believe) and even an Exacto or pocket knife.

You need a tapered shape or upsideside-down mushroom shape to prevent the 'epxoy plug' from pulling out of the deck and deck core. See photo. But it doesn't need to be round, tapered, or even pretty! I have also resorted to 'scoring' deep cuts or lines around the ID of hole and have even drilled into the sides of the hole ... anything to create a MECHANICAL LOCK for the epoxy to grip onto and hold tight in there.

Then just wait for it to cure and then tap drill the epoxy plug for the 'body' diameter of the wood screw you will use. You can even use waterproof 2-part or 5-minute epoxy.

Simple and works ... and far better than just a screw into wood IMHO.
 

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Bryan A.":1cayuw4j said:
How do you keep the epoxy in? Cabosil?

Good point! For any SUPER structural, yeah, a filler like cabosil, microballoons, kitty hair (no, not REAL kitty hair) or even sawdust can or perhaps 'should' be used. For the average install, in my experience even an epoxy tapered or mushroom-shaped plug (upside-down) made of 5-minute epoxy will stand up for years.

Watch out though if you ever need to sand ... your filler WILL make a difference in the work it takes and the final results. Ugh ... ask me how I know ;) ?
 
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