On this project there is one log that will need to be replaced as it is beyond repair. I could use the Liquid Wood to stabilize and harden it – but the face of the log has deteriorated to the point that I would not be able to rebuild it. If the face of the log were to be painted then I could rebuild using WoodEpox – shaping to mimic the wood then paint – but since this is natural wood that is not an option.
In some cases I have actually removed just the face of the log and after stabilizing the wood – replaced the face.
Here you can see that this 8″ log is more than half gone. The log runs to and then underneath the sill of a window. The sill is also rotted. Rather than use liquid wood – I have chosen to replace the sill. Removal of the log is easy – It is only 8″ diameter and 24″ long. The Lodge is built using American Chestnut which is not available (American Chestnut suffered the same fate as the American Elm having been taken out by blight early in the last century).
The lodge is constructed using a butt and pass system as discussed on an earlier post. Logs in a wall are adjoined using iron spikes that have been driven down through the top of the log from and through the log above. Additional spikes or re-bar are driven through the log to the log below. In addition Spikes are Drive horizontally through adjoining logs — This makes for one tough and strong wall. In this case I cut the spikes using a reciprocating saw and once those spikes have been cut I am able to pry the log out.
Installing a new log I will have to Drive in spikes from the end as well as angle spikes from either side.
I dig out the log and any loose material underneath the sill and the sill itself.
I have remove the window sill and have select a 2 x 8 that I have in stock to replace it. I measure the window sill and make a duplicate. I paint Liquid Wood on to the bottom portion of the remaining window frame and will build that up with WoodEpox.
Being that this is a log structure and logs are rarely straight, the build up underneath the sill will be just as is was before — a combination of wood and mortar chinking. Once I have built up log below the sill I can install the window sill then tuck with chinking underneath to complete the seal. Ill be using WoodEpox to reform the bottom of the window frame. Once cured the window frame and sill will be sanded, primed and painted.
The wood of choice for log replacement is either Ash or Beech as both grow straight and the grain, color and properties are more similar to that of American Chestnut than other options. Ash is my first choice as it will blend in better than anything else. Besides, its always nice to get my hands on a fine piece of Ash.
Now that the log is removed I clean all surrounding surfaces removing all nails, spikes and of the like and then dust all the surfaces with boric acid.
My next step is to select, inspect, peel and prep the log that will replace the one I removed. I contact local arborists, tree trimmers and firewood folks in the area in search of the right log.
In the meantime I can continue with the rest of the project and get other parts of the wall insulated and chinked.
{ 5 comments… read them below or add one }
I have a hunting cabin and the top log on the gable end has rotted out it goes behind a four foot wide block chimney any ideas?
I can’t telll you how much I appreciate your website on log repair. I currently have a cabin that needs for lower logs replaced that are stacked on top of each other. I live in Idaho and the winter storms pound that side of the cabin. Since I’m retired with reduced funds I would like to do the repairs myself with a couple of friends to help.
Would I start from the lowest log and go up? Any additional help would be appreciated. Thanks again for all the great information!
Hello RC – Thanks! I appreciate it. I personally would start with the lowest logs first and work my way up as the worst would be on the bottom however I believe that full replacement of a log is the most drastic action to take and one of last resort. I know that in this particular post I show replacement of a log however the log was too far gone to replace just the face or splice in new wood or strengthen using epoxies. I am going to send you an email with my phone number and we can talk about it further. A few photos would help.
Great to hear! – We would love to see photos of your project!
i realy used your tricks and worked very well.
thank you.
Tee