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How I put in a solar attic fan (and what I’d do differently next time)

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pat_parker
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I get the hesitation around relying on tapes and sealants—especially in the PNW, where “a couple of wet seasons” can mean a whole lot of rain. But I have to ask: have you ever had a flashing job go sideways because of shingle irregularities or an older roof deck that just wouldn’t cooperate? Sometimes, no matter how careful you are, retrofitting metal flashing onto a wavy old roof can end up creating more gaps than it solves, especially if the shingles are brittle or there’s weird decking underneath.

“For me, a low-profile metal flashing (even if it feels like overkill) has been more reliable long-term, especially with irregular shingles.”

That’s interesting—my experience has actually been mixed with metal on older roofs. I’ve seen flashing lift or warp when the deck flexes, and then you’re back to chasing leaks. Not saying tape is foolproof (it definitely isn’t), but some of those new butyl-based tapes hold up better than I expected. I did a solar fan install last year on a 30-year-old comp roof—couldn’t get the flashing to sit flat without tearing up half the surrounding shingles. Ended up using a combo: minimal flashing for structure, then layered tape and high-grade sealant for backup. Checked it after two winters and so far, bone dry.

Curious if you’ve tried any of those newer flexible flashings? They’re not as pretty as metal, but sometimes they’re easier to work into weird spots without prying up half the roof. Or do you just stick with custom-bent aluminum every time?

I guess my main worry is that there’s always some trade-off—overkill on materials vs. risking future headaches. If you’ve got a good system for getting metal to lay right on old shingles, I’d love to hear it... I’m always looking for ways to avoid crawling back into an attic during January rainstorms.


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musician30
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“Ended up using a combo: minimal flashing for structure, then layered tape and high-grade sealant for backup.”

Honestly, that’s what I’ve landed on too. Tried those flexible flashings once—looked like an arts and crafts project gone wrong, but it kept things dry. Metal’s great until you hit those old, lumpy shingles... then it’s just a wrestling match. I’ll take ugly-but-waterproof over pretty leaks any day.


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finance_cooper
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Flexible flashing always looks a bit questionable, but I’ve seen it outperform metal in spots where the shingle plane’s uneven or there’s lots of old patchwork. Still, I worry about long-term UV breakdown on some tapes. Anyone actually opened one up after a few years?


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(@nature384)
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Pulled up a section of flexible flashing on a roof I did about six years ago—wasn’t because it failed, just had to reroute a vent for a bathroom remodel. The tape (one of those butyl-backed ones) was still stuck like crazy, but the exposed edge had started to curl and get brittle. Rest of it, under the shingles, looked brand new. We get brutal sun here in Texas, so UV’s no joke. I’ve seen metal flashing rust or lift when the decking’s uneven, especially on older homes where nothing lines up anymore. Flexible stuff really hugs those weird spots.

But I hear you—some tapes seem to “melt” after a couple summers. Anyone tried layering something over the exposed edge for extra protection? Like a bead of sealant or even some granules pressed in? Curious if that actually helps or just makes a mess long-term.


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Layering sealant over the exposed edge of flexible flashing tape is a pretty common idea, but in my experience, it’s a bit of a mixed bag. Most of those tapes—especially the butyl-backed ones—do a great job under shingles or anywhere they’re shielded from direct sunlight. Once they’re exposed, though, UV will eventually win, no matter what.

I’ve seen people run a bead of high-quality polyurethane or silicone sealant along the edge, and it does help for a while. The trouble is, most sealants chalk up and shrink after a few years in direct sun, especially in places like Texas where that sun is relentless. You might get a couple extra seasons out of it, but then you’re back to the same problem: brittle edges and potential for water intrusion if things start to lift or crack.

As for pressing granules into the sealant—sort of mimicking factory shingle edges—I’ve seen it done on smaller patches. It can help camouflage the repair and might offer a touch more UV protection, but honestly, it doesn’t hold up like you’d hope. Granules tend to brush off over time unless they’re really embedded during application. Plus, it can make future repairs messier.

If you’re set on protecting the tape edge, I’d lean toward using a UV-stable flashing tape as your top layer—something specifically rated for exposure. I know that adds cost and a bit of labor, but it’s less maintenance down the road. I’ve also come across some folks who tuck a thin strip of metal or plastic trim over the exposed edge (basically making a mini-drip edge). That seems to help, especially if you can fasten it without creating new leak points.

At the end of the day, nothing really beats keeping those vulnerable spots covered by shingles or another layer if possible. Once you have exposed adhesive or sealant facing the sun in Texas, it’s just a matter of time before you’re back up there patching again. Wouldn’t call any of these “set and forget” fixes.

If you ever see those edges getting brittle or curling, best to catch it early before water finds its way in... Even small gaps can cause headaches later on, especially after one of our summer storms rolls through.


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