Had a similar headache a few years back when I built a small deck near my pool. Thought stainless steel nails would be bulletproof, but within a year, some started showing rust spots—probably lower-grade stainless or something. Ended up switching to hot-dipped galvanized nails, and they've held up surprisingly well since then, even with constant splashing and moisture.
Agree with the earlier point about ventilation too. Once I added some extra drainage underneath and improved airflow, the rust issues slowed down dramatically. Copper nails sound interesting, but honestly, the price and availability made me hesitate. Aluminum might be worth a shot, though I've heard mixed things about their strength for structural projects.
Anyway, sealing the trouble spots is definitely a smart temporary fix. Buys you time to figure out a more permanent solution without rushing into anything costly or complicated. Good luck with it—rust is always a frustrating battle...
"Thought stainless steel nails would be bulletproof, but within a year, some started showing rust spots—probably lower-grade stainless or something."
I had a similar experience recently when I tackled my first outdoor project—a small pergola in the backyard. Like you, I assumed stainless steel hardware would be the safest bet against rust. Turns out, not all stainless steel is created equal. After just one rainy season, I noticed tiny rust spots forming around the screws and brackets. Pretty frustrating considering the extra cost.
Your point about ventilation and drainage makes sense. Initially, I was skeptical that airflow could make such a noticeable difference, but after reading your experience, I'm reconsidering. My pergola sits on a concrete slab with limited drainage underneath, so moisture probably lingers longer than it should. Maybe adding some subtle drainage channels or even slightly elevating the structure could help.
Regarding aluminum nails—I've heard similar mixed reviews. A friend of mine used aluminum fasteners for his fence posts and swears by them, but I've also read they're prone to bending or shearing under heavier loads or stress points. Given that my pergola has to withstand wind gusts and occasional heavy snow loads, I'm hesitant to risk structural integrity just to avoid rust.
Copper nails intrigued me too at first glance, but like you mentioned, availability and cost quickly dampened my enthusiasm. Plus, I've read copper can react negatively with certain treated woods over time... another headache I'd rather avoid.
For now, sealing trouble spots seems like the most practical short-term solution while I research better long-term options. It's reassuring to hear galvanized nails have held up well for you—might give those a closer look next time around.
Thanks for sharing your insights; it's comforting knowing I'm not alone in this battle against rust and corrosion.
Had the same issue with stainless screws on a deck rebuild last summer. Thought I was being smart by splurging for stainless, but nope... rust spots everywhere after just a few months. Honestly, galvanized nails have been my go-to since then—cheaper and surprisingly reliable. And yeah, airflow makes a huge difference; moisture buildup underneath is sneaky stuff. Sounds like you're on the right track though, hang in there! Rust is just nature's way of keeping us humble, lol.
Curious—did you check the stainless screws' grade? I learned the hard way that not all stainless is created equal... cheaper 304 stuff rusts way faster than you'd think. Galvanized nails are solid though, can't argue there. Moisture buildup is sneaky for sure, but sounds like you're figuring it out. Deck projects always seem easier in theory, right? Hang tight, you're getting there.
"Deck projects always seem easier in theory, right?"
Haha, isn't that the truth... I swear every time I tackle a deck or fence, it turns into a weekend-long saga. Learned my lesson on stainless too—316 is pricier but worth it if you're anywhere near moisture. Hang in there, it'll pay off eventually.
