Fixing broken wooden fence (with welding)

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12 year old wooden fence broke after 60mph winds.  Several pressure treated 4x4's snapped at ground level.  The wood was saturated with water over time and rotted through.  Coupled with a weed wacker cutting into the 4x4's, they finally gave way.   So, I yanked out the old concrete-set wooden posts with a Hy-lift jack and chain.  Poured new concrete bases, bought new pressure treated wood and coated the bases with "Henry's #107" (Home Depot).  That was three years ago.  Fast forward this time.... A few months ago, the "every three year" hurricane winds returned.  News said they gusted at 70mph.  Well, this time the other fence line broke and fell over, involving a different neighbor.  Three 4x4's were again rotted out and snapped at ground level, knocking a huge portion of fence into the neighbor's yard. Several other 4x4 pieces were loose and are rotting away at the base as well. What to do in an "easier" fashion this time???I said, "screw the back-breaking digging and pulling out the old concrete bases."  Since my neighbor is busy at work all the time and I like building things myself,  I thought I'd try something different.   I went with the "Oz-Post" fence mender (model #T4-600).  Real quick, you cut off the old wooden 4x4 stumps at ground level with a sawzall.  Pound the new galvanized oz-post right into the old cut-off wooden stumps that's already seated into existing concrete bases.  Install new treated 4x4 and bolt it in.  Done. It's solid as a rock, seriously! Video demo I found:Then, for existing 4x4's that didn't totally snap off at the base (yet), I used these little darlings:"E-Z Menders" (Home Depot brand @ $10.00ea.)You pound them in between the 4x4 base and concrete.  Yes it goes right through the wood set into the concrete base.  For best results, use the EZ  mender for both sides of the still standing 4x4 (one on my side and one on the neighbor's side).Video:Part 2 (welding), coming up.  Gimme a minute....Last edited by SuperArc; 01-30-2014 at 03:19 AM.Lincoln Power Mig 216Lincoln AC/DC-225/125Miller  625 X-Treme PlasmaMiller 211 Forney 95FI-A 301HF 91110Victor Journeyman O/PMilwaukee DaytonMakita  Baileigh NRA Life Member
Reply:Well, those EZmenders work pretty good, IF.... you can place them on BOTH sides of the fence.  My neighbor had a  metal shed permanently affixed to a concrete slab directly behind his side of the 4x4's and access to them was a no-go.   So, after I installed the EZmenders on my side of the fence, I still didn't like how the fence wasn't 100% sturdy enough for my likings.   (Wife disagreed, but she's a "girl."  What do they know?   )So, I had some 7/8" rebar laying around and 3/16" x 1 3/4" x 1 3/4" angle iron from another project.  This is what I did. I cut the rebar into 4' lengths each. The rebar was spaced directly adjacent to the edge of the unseen concrete post footings.  The pics will explain the rest.... Attached ImagesLast edited by SuperArc; 01-30-2014 at 03:26 AM.
Reply:Rebar was welded to the angle iron.  Angle iron was welded to the EZmenders.  Rust colored primer coat was added and it will fade to a closer color of some of the red wood. The fence doesn't move now.  My fat @$$ sat on top of the fence to test out the rigidity and it's solid.   Will the rebar rust below ground level? Probably, but I only need it to last for 9 years and I'm moving.  Also, those two supports I made are not in plain view of the back yard.  It's on the side of the house and trash cans sit in front of them.   This entire fix was sooo much cheaper than cinder block or vinyl fencing.  We got a quote just for one side of vinyl  fencing at $3,500. This entire project with wood, screws, EZmemder, beer and oz posts only cost us each $158.00.  I didn't count the rebar into the cost, because I've had it for a few years and it was just a "wash" in my mind.  Does it look pretty? No.  Does it work however?  Yes. Did I save a ton of money and less strain on the back? Hell yeah. Bring on the wind.Last edited by SuperArc; 01-30-2014 at 03:25 AM.
Reply:That's a pretty slick idea! Never seen that before. My youngest daughter and son n law put up about 200-feet of fence with treated 4x4s bought at Lowes, the post rotted off at the ground level in less than 3-years!Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Originally Posted by CEPMy youngest daughter and son n law put up about 200-feet of fence with treated 4x4s bought at Lowes, the post rotted off at the ground level in less than 3-years!
Reply:Hmmm....nice close up pics of everything...except the weld- what's up with that superarc?  I like the posts that get pounded into the old rotted ones - pretty cool idea.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:That's pretty much what the local mom & pop lumber yard told her. I'm trying to talk her into going with railroad ties this time. Their fence runs east and west, the majority of our hard winds come out of the south. They live up on the hill over looking my pasture, no trees south of their fence for about 600-feet! Of course I'll have to put the post hole auger on the tractor, and go up and drill all new holes for them. Funny my dad would have had me do it by hand! Don’t pay any attention to meI’m just a hobbyist!CarlDynasty 300V350-Pro w/pulseSG Spool gun1937 IdealArc-300PowerArc 200ST3 SA-200sVantage 400
Reply:Originally Posted by SuperArcRebar was welded to the angle iron.  Angle iron was welded to the EZmenders.  Rust colored primer coat was added and it will fade to a closer color of some of the red wood. The fence doesn't move now.  My fat @$$ sat on top of the fence to test out the rigidity and it's solid.   Will the rebar rust below ground level? Probably, but I only need it to last for 9 years and I'm moving.  Also, those two supports I made are not in plain view of the back yard.  It's on the side of the house and trash cans sit in front of them.   This entire fix was sooo much cheaper than cinder block or vinyl fencing.  We got a quote just for one side of vinyl  fencing at $3,500. This entire project with wood, screws, EZmemder, beer and oz posts only cost us each $158.00.  I didn't count the rebar into the cost, because I've had it for a few years and it was just a "wash" in my mind.  Does it look pretty? No.  Does it work however?  Yes. Did I save a ton of money and less strain on the back? Hell yeah. Bring on the wind.
Reply:Originally Posted by docwelderyou just had to drag in some welding for a wood-working project?
Reply:Nicely done!  I wouldn't worry too much about "7/8 inch" rebar rusting through anytime soon. I've had some 3/4" in the (wet) ground at my place for over 20+ years that I finally removed.  The surface of the rebar that was buried in the soil was ugly, but after cutting a piece for schits & giggles, I was surprised at how nicely preserved the center of it held out.   Plus, your rebar isn't supporting a house or anything really critical. "Hey I didn't come to look and learn, I came to turn and burn.... If I can't light up, I'm gonna light out!"-JodyIdealarc 250 "Fatman"MM 252MM 211 "Little boy" Victor Torches
Reply:Nice save bud! Time for a Hamms break now! And way to get spray paint all over the fence there champ!  I hate being bi-polar it's awsomeMy Heroes Have Always Been Cowboys
Reply:Originally Posted by weldermikeNice save bud! Time for a Hamms break now!
Reply:Originally Posted by DSWWelcome to the  wonderful world of "new" ACQ treated wood... Most of the older CCA lumber was  ground contact rated. I've got a shed platform made up of older CCA treated 4x4's and 6x6's that's over 30 years old with no signs or decay. The newer 4x4's that are ACQ treated last about as long as the ones you mentioned did. The ACQ treated lumber also eats fasteners really quick as well if they aren't specially treated. They'll rust thru standard framing nails in 6 months under the right conditions.
Reply:Treated lumber in ground= bad, treated lumber in concrete = worse yet. Better to dig a deep hole and use fine gravel around it. If you use concrete only fill the holes no more than halfway .When you dig the hole best way is to make it like a bell, bigger around on the bottom . Repair should hold up good now.Miller xmt304,  Miller S22 p12, Miier Maxstar SD, Miller 252 w 30A, Miller super32p12, Lincoln Ranger 9, Thermal Arc 181I with spoolgun, Hypertherm 10000 ,Smith torches. Esab 161lts miniarc.
Reply:Great idea for fixing the fence.
Reply:That's one serious fence, I think it will last for many years even on extreme weather conditions. Great idea and great job!
Reply:Ill tell you. the wonderful world of welding, I am new at welding actually today was first time. please not even ask, it went horrible but ill keep practicing, I do a bit of landscaping and let me tell you I would never never could come up whit something like this, of course I never weld I would  had to replace post and whatever need it. now I can give my customer another option, I like that, thanks for sharing. the paint job  mm well I charge so I would have to do a little better, not complaining or anything.. heheh  uff
Reply:Originally Posted by CEPYou gotta like his style! I'd rather stick something sharp in my eye than work with wood.