This repair is continued from Part 2.
Drywall Repair Panel
I purchased a 2ft x 2ft x 1/2in drywall panel for ~$4 and marked a 6in by 6.5in square in the corner to fit the hole I cut in the basement ceiling. (If you have a scrap piece of drywall laying about, that will also do fine.) The curve in the bottom edge of the panel in this photo is a fisheye artifact from the camera lens.
Fitting the Drywall Patch Panel
Here’s the new repair panel compared to the water damaged drywall section cut from the ceiling. I used a sawzall blade to the cut the panel because it has finer saw teeth for a cleaner cut.
The drywall repair panel is trimmed to fit with the utility knife and fastened with four drywall screws to the plywood backer board and the metal runner of the suspended ceiling.
Tape and Mud the Drywall Joints
Self-adhesive fiberglass drywall joint tape is applied to the four joints of the repair panel. A thin coat of joint compound applied with a 4″ or 6″ blade. Click on the photo for a larger version. If you look closely, you can see the weave of the fiberglass tape.
I forgot to take a photo of the fiberglass joint tape before I applied joint compound to the ceiling. This next photo illustrates the process from a job I was doing on the wall.
Apply Finish Coats of Joint Compound
Immediately after the fiberglass tape joints are mudded (“mud” is slang for drywall joint compound), spread a thin coat of drywall compound using the 12-inch blade, feathering the edges. Don’t delay because those feather thin layers of mud start to dry in minutes and will gum up the blade leaving long tracks in the finish.
Tip: With drywall compound, “less is more“. The less you spread on the less sanding you’ll have to do later.
The next photo is the ceiling patch after the first application of drywall compound with the 12 inch blade. I left this to dry overnight before sanding.
Drywall Wet Sanding
The next day, I used a wet sanding sponge to smooth the high spots and feather the repair into the main ceiling. A drywall sanding sponge is a sponge made with an abrasive surface. Dip the sponge in a bucket of water, squeeze out the excess water so it’s damp, and sand with almost no dust. Rinse the sponge in water as needed to remove the joint compound that will clog up the sanding surface.
After sanding, I applied a very thin second coat of joint compound with the 12 inch blade, let dry and wet sanded. Here’s the ceiling patch ready to be painted. The nearly white-on-white doesn’t contrast well for the camera.
If you look closely (click on the photo for a larger view) you can see the brighter edges of the new paint where I painted the ceiling patch. I took a small sample of the ceiling to the local paint store for a computer color match, but as the salesman explained, the computer isn’t perfect and whites are especially hard to make an exact color match.
I hope this project saves you some money!
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