Drywall Repair Around Bathroom Fan

I've got my exhaust fan installed in the ceiling of the bathroom, now I'm wonder how best to seal the gap around it. The fan housing is obviously sheet metal, and the ceiling has the plastic vapor barrier on top of the drywall. Would metal tape work for this or is there something better to use? The fan can be covered up to R40, so once the physical gap is covered I can back-fill the insulation. I'm just wondering what will stick reliably to both sheet metal and the plastic sheet. Sealing the vapor barrier You'll want to seal the vapor barrier to the fan housing using an acoustic sealant like OSI® SC-170™, or similar product (you might have to do this from above). Just make sure the sealant is approved for use with vapor barrier, some sealants won't adhere well to the vapor barrier. If there is enough plastic to lap up the side of the housing about an inch, this will be a simple task. Fold the plastic back away from the housing, apply a bead of sealant around the housing, then push the plastic into the sealant.

If there isn't enough plastic to attach to the fan, you'll have to make a gasket. Simply cut a square of plastic larger than the fan housing, then make a cutout that will fit the fan. Leave the excess from your cutout attached, so you can attach the plastic to the housing. Use housewrap tape to attach the gasket to the existing vapor barrier, then follow the steps above to seal the plastic to the fan housing.
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Just put the fans face trim on, and enjoy. If you really want to, you could run a bead of silicone caulk around the housing. If the gap is ~1" or less, you should be able to easily fill it with joint compound. It might take a few coats to fill the gap, since you don't want to put it on really thick or it will take a long time to dry. Once the gap is filled, feather the compound out to blend with the surrounding wall. You can use a 10"-12" taping knife for this. Once you have a gap ~1"-2", it's time to start thinking about making the hole larger and patching it with another piece of drywall. You might be able to fill the gap with joint compound, but it will be much more difficult than with smaller gaps. If the gap is larger than 2", you're going to have to make the hole bigger before you can make it smaller. Cut out a square of drywall around the fan, until you get to the center of a joist on each side of the fan. Cut a new piece of drywall to fit the hole you just made, then cut out a hole in this piece to fit your fan housing.

Make sure the hole for the fan is very close to the outside dimensions of the fan housing, so you'll end up with a very small gap. Tape and mud the joints, prime, and paint. Finally, follow the steps above from the "Very Small Gap" section. You could use a spray foam insulation like Great Stuff. It sticks to just about everything and expands to fill voids.Browse other questions tagged ceiling exhaust-fan weatherstripping or ask your own question. Make the right drywall repair for a seamless transition before applying new paint Invest a little time and energy and make wall repairs the right way before investing in a new paint job. You can patch large and small holes in wood, drywall and metal as long as you have the right type of patching and repair products on hand. This buying guide highlights the different types of compounds and plasters available, along with other accessory products to help make your patching job complete. SHOP ALL PATCHING COMPOUNDS Compounds are workable for a select period of time and can be shaped and manipulated before hardening.

Joint compounds are often referred to as “mud” and can be used for taping and texture. Spackling compounds are ideal for repairing hairline cracks and must be applied quickly as they are only workable for a few minutes. Glazing compounds are ideal for use with wood and metal window sashes. Sand and clean surfaces thoroughly prior to applying joint compound. Resistant to moisture and extreme Remains semi-elastic under a firm, wrinkle-free film Glazing single-pane glass windows into wood or metal sashes Available in powder or ready-mixed form Available in quick-set formula Comes in bags, buckets, boxes or Drywall construction or repair May be used for both taping and texture Ready mixed for easy use Expands and contracts with surface it's applied to, helping to prevent future cracks May be used indoors or out May not be able to be sanded Repairing cracks in wood, drywall, plaster, concrete and masonry

Designed for fast, efficient application Can be painted over within 1-5 hours Plaster products come in powder form and once mixed with water, result in a paste-like substance. Plaster is used for interior plaster repairs and generally dries in a short period of time. To help plaster adhere, wet the surface of the plaster wall you are repairing prior to applying it. Plaster of Paris is easy to mix and works well for filling holes in interior plaster walls and ceilings. It can set quickly, so avoid mixing too much. Plaster dries uniformly and can be painted over and textured to match the surrounding surface. Comes as a powder that must be Repairing surface cracks and large holes in plaster walls and ceilings Repairing fine cracks and small holes in plaster or wood May set in a matter of minutes Can be sanded and painted Comes in the form of a white powder that must be mixed with water Setting bathroom wall fixtures Repairing plaster and drywall

Casting, modeling or sculpting for hobby use General Patching and Repair Compound accessory products, like putty, epoxy and tape, can be used for patching projects. Putty is a versatile substance that provides strong adhesion and can be used to fill holes, cracks, joints and other defects in wood. Epoxy provides a strong bond and can be sanded and carved after it hardens. Tape can be used in conjunction with compound and plaster to repair drywall. Make sure the repair product you use is compatible with the surface in need of repair. GENERAL PATCHING AND REPAIR Usually white or metallic in color May be liquid or putty Comprised of a resin and hardener Repairing auto bodies, appliances, plumbing, rain gutters and garden tools Repairing and protecting wood Provides continued flexibility after application Rain gutters, roofing, interior walls and wood surfaces Available in dry or pliable form Some types may be stained, painted or varnished