Shopsmith Forums

For a long time, I have used aluminum foil tape on exterior and interior wood and plaster repair projects.

The tape is Nashua brand #322. This is the "original duct tape" as used in HVAC work. I think it is about 0.005" thick. Nashua makes other grades which are thinner. This tape has a paper backing which when removed exposes a really strong rubber cement - like the kind used in laminate countertop work. Once stuck in place, the foil really stays put. There is some visible "print through" when tape layers overlap, but is not too visually objectionable.
My main use for this tape is to preserve old weathered exterior wood, such as window frames and sills, from further deterioration. I expect that a metal foil will permanently seal the wood from further weathering and sun/rain/condensation damage, and the tape also "smooths out" seams, putty work, knots, nail holes and many other surface defects. Aluminum foil takes paint very well. When painted, the foil "disappears" and the surface looks much improved.

I am currently using this tape on both old and new wood work - to blend them together and make the seams disappear. Careful application minimizes wrinkles. Burnishing the foil with a wood block will smooth out small wrinkles.

I think surface taping is a useful innovation for wood project finishing. I really cannot think of a downside to using tape on woodwork in this way, but I have not seen anyone else doing this. We will not be able to "sand" foiled wood, but we should not ever again NEED to sand if the tape preserves the wood as we expect. So far, tape I applied 10 years ago is still OK.

I have not used foiling on anything like outdoor wood furniture, trellises, etc, but I do not see why foiling would not enable ANY outdoor wood projects to last "forever". i suppose that after decades the adhesive could fail, but as I mentioned, the adhesive is really strong and not water soluble, and is protected under the foil itself plus paint layers, so it sees no sun or rain, and nor does the wood.

Have I found the secret to wood project immortality?

Very interesting.

I have to replace some window in an older house and shop.

This is a very good idea.

I keep meaning to post in this thread but I keep getting distracted.

I remember back in the 70s foil tape like this was touted in Popular Science and elsewhere as a miracle solution for sealing joints on outdoor structures, and it kinda is. It seals well, doesn't break down from UV light and other environmental conditions. It's very long lasting also. Never realized it was easily paintable also. I can think of several uses for it on my old log cabin. I actually have some duct tape on the seams where the roof boards meet the top of the log walls that I never pulled off when I was removing a hideous coating of paint off the logs. Under the eaves it's been protected from the environment but the backing has decayed and you can see that it's nearly nothing but fiber and glue now. I have to pull that off at some point. It would be a major task to install molding that would seal the uneven joint between logs and the milled roofing boards. I could just use foil tape to seal the joint, and even if I would undertake installing molding I could start with a layer of foil tape first to guarantee a seal that air, moisture, and bugs won't penetrate.