Dry-flex window and door repair care

The Dry Flex woodcare system for doors and window restoration in Sussex

This is one of the best products invented in the late 1980’s. It has been tested in extreme conditions in Austria at a altitude of over a thousand metres. It gave the product severe climate conditions which were tested continuously.

The company took over 16 years to perfect this product which is a 2 part epoxy resin for metal, stone and more importantly wood. We have been working with this product for many years now and we choose to use 2 different types of Dry-Flex resin. The main ones we favour are the 1 hour and 4 hour resin.
Both have different a compound bases and can be used in different heats of the day, thicknesses and more critically, time.

The 4 hour is our preference. We favour this because you have a better working time with the 4 hour Dry Flex. When you are splicing timbers onto the stiles of the windows. You have to make sure that every thing is straight on both sides of the window – depth, width and length.

Using Dry Flex wood repair in the heat can be difficult

One example, we were restoring 14 casement windows in the middle of summer. Using one hour Dry-Flex you would have a working time of about 3- 5 mins. You can splice maybe one or two windows in this time. Using Dry Flex 4 you have a working time of 25 mins which means that you can get a greater amount done. You aren’t panicking if the windows are not completely level and straight and if they aren’t than you can easily rectify it. Most importantly, the quicker we are, it reduces the cost and this always gets passed down to the customer.

The compound of both of these products are slightly different. One hour resin is perfect for small repairs of up to 10 mm in thickness. But with the 4 hour you have double the thickness and it doesn’t react as quickly as the 1 hour in hot summer days when we get them.

Preparation for restoring windows and doors with Dry Flex

When we first visit and evaluate a job, we would determine how bad the rot is on your windows or doors. We would then assess whether it was more cost effective to have a new bottom rail or mid-rail installed. This is where other companies would tell you that you need new windows.

components of a sash window construction for sussex sash window restoration
this picture shows the components of a sash window.

This is not true and can be repaired easily with skilled qualified tradesmen. The only thing that we have to know as a company is at which point do we replace the damaged window part or repair. This is usually determined by how much of the product would be used and how far has the rot gone through to the other side.

We repair all our windows to English heritage standards at all times and endeavour to keep the windows at all cost. This is because seasoned wood will last for centuries with the right care. The oldest sash windows still in date from 1670. We have a history page on this subject that is very interested about how windows have evolved.

Rotten Mortise and Tenons are not a problem with the Dry Flex wood-care system

Upon starting the job we would always take all the paint off the windows or doors, back to bare wood to see exactly how far the rot has gone. This would then be all cut out until we can see a nice tight grain again with no discolouring. This could even include the Mortise and Tenon joints of the windows or doors.

If a mortise or tenon has gone than we would install a new stretcher timber into the bottom, mid or top rail. Then we would
Dry Flex this into position creating the perfect Tenon joint. We would Re-install the rail back into position to the stiles creating a perfect window again.

This was a project that we did at Brunswick Square Hove East Sussex, please click the link to see more

When we splice timbers to the rails or the stiles we either use Polyurethane glue and cut out a grove where the timbers meet. This will fill with Dry Flex or we would splice together just using Dry Flex. Dry Flex is also a gap filling adhesive as well as a filling compound.

It is done by using 2 different glues called Dry-fix. One is a wood stabilising compound adhesive, and the other has a wood hardening process. So to do this process you need to buy 2 different 2 part products. At a cost of £40 per set this can be a very expensive product to try. especially to use if you haven’t got the experience or knowledge.

We can restore your windows in just one day

Once the Dry-fix adhesive has been left for over 20 mins to cure than you can start to mix up the Dry Flex compound. With the one hour you can smell the Ammonium in the product and we do warn customers of this. Some people think that we have just let one go, which can be a bit embarrassing on the customers part if not forewarned.

Next we would install the compound in the area that has had the rot and leave to cure. The one hour is perfect for small minor repairs. Within this hour we would shape the product with osculating tools, routers and chisels. All the excess on the wood has to be removed because this would act as a barrier against the paint adhering to the wood.
Dry Flex needs a gap to adhere to and needs a minimum of 3mm to be effective or otherwise it will peel away.

Dry Flex never cracks again and opens up letting in water

The product is called Dry Flex because it has a subtle flexible property in it making it perfect to splice timber together. When you have old and new timber these have a different water content and different shrinkage rates. Using Dry Flex with the spliced timber you have something that moves with the wood in the different seasons.

Two pack filler does not have this property and cracks at all the joints where it is used. Therefore you have something that can take away the pressure of the movement of the timber and not leaving gaps again. This is so important, because this is how your windows or doors have got rotten in the first place by allowing water ingress into the wood itself.

We hope that this has been a little bit more informative than other websites and not too boring. We have to explain the difference between these products and why we use them. Please take a look at how we restore your windows and doors and refurbishment of your windows and doors. You can see the full process of how we complete these services and what we can do for you.