Epoxy is available in a range of formulations for various applications. Most consist of two parts – an epoxy resin and a hardener. When mixed, a chemical reaction causes the epoxy to set up (harden). The time it takes to set up depends on the chem­istry of the hardener. Some epoxies set up within one to five minutes while others can take many hours.

For woodworkers and DIYers, the most popular formats are the two-part, five-minute (quick-cure) and 30-minute (slow-cure) epox­ies, often referred to as general-purpose epoxies. As the name implies, once the resin and hardener are mixed, they set in five or 30 minutes. They reach handling strength in about one hour (up to about eight hours for some 30-minute epoxies) and are fully cured after about 24 hours. Bonding strength varies. With a bonding strength of around 4,500 psi, 30-minute epoxy is about 10 per cent higher than Titebond III glue, while five-minute epoxy has about 3,500 psi bond strength. However, both epoxies are more than adequate for most jobs wood­workers are likely to encounter in the shop.

Two main formats

Five- and 30-minute epoxies are available in dual containers or a syringe container. Dual containers consist of a resin and a hardener you dispense and mix by hand. Some are dispensed in a ratio of 2:1 resin to hardener, others in a 1:1 ratio.

Syringe containers come in a dual car­tridge with an integrated syringe that’s especially convenient for small jobs in the shop and for DIYers. You simply press a plunger to expel the correct ratio through a nozzle and then mix the two components by hand.

Using epoxy

Using two-part epoxy isn’t overly com­plicated. The resin and hardener are very sticky and have a noticeable odour that can cause an allergic reaction such as an itchy rash for some people. If you have dermatitis or if you’ll be mixing a large amount of epoxy, it’s a good idea to wear a respirator and gloves. When using dual containers mix only as much as you can use at a time. Once mixed, the epoxy will quickly and irreversibly harden. Using a thin piece of wood or a plas­tic spatula stir the mixture thoroughly as per the manu­facturer’s instructions. This is an important step as most epoxy failures result from inadequate mixing.

For small projects, such as adhering a steel bolt into a wooden door handle, you only need to apply epoxy to one surface. Don’t apply too much otherwise it will ooze out of the assembly. It takes a bit of trial and error to get a sense of how much epoxy to use. For larger assemblies spread the mixture on both surfaces and then lightly clamp the setup for at least 30 minutes to ensure the bond sets correctly. Wipe up any excess epoxy before it hardens using a rag moistened with isopropyl or acetone. An overly tight bond between the two parts being epoxied isn’t necessary and is usually not recommended.

Epoxy also comes in a putty format that looks and feels like modelling clay. It’s useful for bonding and filling jobs around the home. You won’t get your hands all sticky using this stuff, though if you have dermatitis wear gloves. Simply cut off as much as you think you’ll need for the job and knead the putty by hand, making sure to wash your hands after kneading the epoxy. The epoxy is then ready to use. It’s pliable enough to push into holes, cracks and crevices, and around leaky pipes. Once cured it’s hard as rock.

There are several brands of two-part epoxy on the market. All are viable products distinguished primarily by bonding strength, delivery format (dual containers or syringe cartridge), container size and price. Once you get into larger epoxy pours for river tables there are some other properties you’ll want to consider. Most big box stores carry epoxy in the syringe cartridge format while specialty retailers primarily carry dual containers. And, of course, you can order just about all these products online.

I use epoxy for securing wooden handles to chisels, for bonding small bolts to shop-made door and drawer handles, for bonding metal nuts on shop-made jigs and fixtures, and whenever I need to bond dissimilar materials. You’ll undoubtedly find your own uses for this incredibly useful shop accessory.