Posted by MarkB_MI on November 04, 2015 at 16:37:10 from (70.194.0.153):
In Reply to: Tin over plywood posted by dhermesc on November 04, 2015 at 09:56:22:
I would not put any time or money into salvaging this failed project. It sounds like he cut so many corners you would be better off starting from scratch.
It's possible to make strong, watertight structures from plywood. They're called "boats" and I've made one myself. But you don't make them out of lauan, 2x2s and polyurethane varnish. You use marine plywood and epoxy resin. Marine plywood has no voids where water can collect; it is not cheap. If the builder hasn't been able to fix the leaks, that lauan is already disintegrating inside. And I would assume he got the rest of his materials at Home Depot, so he probably didn't use any corrosion-resistant fasteners.
As for the polyurethane finish, there are very few urethane varnishes that are suitable for exterior use. Those that will stand up to the weather are very expensive, upwards of 50 bucks a quart.
That said, you have nothing to lose but a few hours of your time and and a few hundred bucks worth of aluminum and screws. Good luck.
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