I totally get the frustration with aluminum flashing—been there myself more times than I'd like to admit. But honestly, before you jump straight to replacement, have you considered just working around the kinked area? Depending on where it's located and how visible it is, sometimes you can strategically reposition or overlap flashing sections to hide imperfections without compromising function.
Also, while the rubber mallet trick can work wonders for minor dents, I've found that using a wooden block as a buffer between the mallet and flashing helps distribute the force even more gently. It gives you a bit more control and reduces the risk of accidentally stretching or warping the metal further. Learned that one the hard way after spending an afternoon making a small dent into a bigger mess...
On another note—and I know this might sound like I'm pushing my green roofing agenda here—but if you're already considering replacing damaged flashing, have you thought about alternative materials? Copper flashing, for example, is pricier upfront but lasts forever and actually looks better as it ages. Plus, it's recyclable and eco-friendly. Or even galvanized steel might be worth checking out—it's sturdy and easier to handle without accidentally bending it out of shape.
Still, I agree with your point about not beating yourself up over this stuff. Roofing projects always seem straightforward until you're actually up there wrestling with stubborn materials on a ladder. I've had my fair share of "why-did-I-start-this" moments mid-project. Just part of the DIY journey, right?
Anyway, just throwing some ideas out there—sometimes stepping back and reconsidering your options can save you from unnecessary headaches down the road.
I've had mixed results trying to salvage kinked aluminum flashing. One time, I tried repositioning the damaged section like you suggested, but it ended up creating a weird overlap that trapped moisture... not ideal. Copper sounds interesting, but have you noticed any compatibility issues when pairing it with aluminum gutters or other metals? Heard mixed things about galvanic corrosion, so just curious if that's been a problem for anyone.
Copper definitely has some appeal, but pairing it directly with aluminum can be tricky. Galvanic corrosion isn't just theoretical—I've seen cases where copper flashing and aluminum gutters caused noticeable deterioration within a couple years. If you're set on copper, consider using isolation materials or coatings to separate the metals. Personally, I'd stick with aluminum flashing replacements or maybe stainless steel as a compromise... less headache down the road.
Had a similar issue a few years back—client insisted on copper flashing with aluminum gutters. We tried isolation tape, but honestly, it felt like a temporary fix. Wonder if stainless steel would've been the smarter compromise long-term?
"Wonder if stainless steel would've been the smarter compromise long-term?"
Stainless steel could've been a decent middle ground, but honestly, mixing metals always feels like a gamble to me. Even with isolation tape, you're just delaying the inevitable corrosion issues—especially in areas with heavy rainfall or coastal exposure. Had a similar scenario myself a while back; we ended up redoing the flashing entirely after just two years because the corrosion was already noticeable. Makes me wonder if anyone's had success with anodized aluminum flashing instead? It's supposed to offer better corrosion resistance, but I've heard mixed reviews on its long-term durability. Curious if anyone here has firsthand experience with anodized aluminum holding up better over time...
