I've been there too—cutting corners once cost me a whole weekend redoing flashing on my uncle's garage. Thought I'd save time skipping primer, and a month later, there I was again, climbing that shaky old ladder he refuses to replace. Lesson learned, though: prep is king, especially when weather hits metal surfaces. Sounds like you've figured it out now, so you're probably good for the long haul. Nothing better than finishing up a job knowing you won't be back up there anytime soon... unless it's to help out a buddy who made the same mistake I did.
Been there myself, and yeah, prep is definitely key. But honestly, even with perfect prep, aluminum flashing can be tricky—especially if you're dealing with harsh weather or temperature swings. I've seen properly primed stuff still fail after a few rough winters. Sometimes it's just the material itself... or maybe my luck. Either way, sounds like you've got it sorted now—fingers crossed you won't be back up that ladder anytime soon.
"I've seen properly primed stuff still fail after a few rough winters."
Yeah, aluminum flashing can be finicky even when you do everything right. Curious if anyone's tried alternatives like vinyl or galvanized steel—do they hold up better long-term, or just different headaches?
I've switched from aluminum to galvanized steel flashing about five years ago, and honestly, it's held up noticeably better through harsh winters. Aluminum always seemed to get brittle or corrode around the edges, even when I was meticulous about priming and sealing. Galvanized steel, on the other hand, has been pretty solid—no significant rust or deterioration yet. The only downside I've noticed is that it's a bit tougher to cut and shape compared to aluminum, so installation can be a little more tedious.
As for vinyl... I tried it briefly on a small shed project, and while it was super easy to work with (cuts like butter), it didn't inspire much confidence durability-wise. After just two winters, it started warping slightly in spots exposed directly to sunlight and temperature swings. It might hold up better in milder climates or shaded areas, but I'd hesitate to use it again on anything critical or highly visible.
One thing worth mentioning: if you're sticking with aluminum or galvanized steel, make sure you're using compatible fasteners. Mixing metals can accelerate corrosion significantly—I learned that the hard way when I first started DIY-ing my roof repairs years ago. Stainless steel screws or nails are usually your safest bet.
Overall, galvanized steel seems like the sweet spot between ease of use and long-term durability. It's not perfect (nothing ever is), but it's given me fewer headaches than aluminum or vinyl over time.
Galvanized steel definitely holds up better, especially in rough climates. One thing though—have you had any trouble bending or shaping it around tricky corners or joints? I find aluminum easier for tight spots, despite the durability trade-off... Curious how you handle that.
