Totally agree—sealant really can save the day when you're dealing with roof penetrations. Flashing alone is rarely ever foolproof, no matter how careful you are. I've seen plenty of installs that looked textbook-perfect at first glance, but once Mother Nature throws a curveball (like a heavy storm or even just extreme temperature swings), tiny gaps and pinholes can quickly turn into headaches.
One thing I'd add from experience: it's not just about getting the right materials, but also about the prep work and application technique. A lot of DIYers (and even some pros, honestly) underestimate how important it is to clean and prep surfaces before applying sealants or roofing cement. Dust, dirt, or moisture trapped underneath can cause adhesion issues later on, leading to leaks down the road. I always stress taking that extra few minutes to wipe everything down and make sure it's bone-dry before sealing anything up.
Also, when you're working with solar attic fans specifically, remember that vibration from the fan motor can sometimes loosen things up over time. I've seen cases where a perfectly sealed install developed leaks months later because vibrations gradually broke down the sealant bond. So it's worth periodically checking your seals and fasteners—just a quick visual inspection every season or so—to catch any potential problems early.
Glad you caught yours early enough to avoid major damage. Nothing worse than thinking you've nailed a job only to find out later you missed something tiny... been there more times than I'd like to admit.
- Good point about the vibrations... hadn't thought of that before.
- Had a similar issue last summer—thought I nailed the prep, but turns out humidity got me anyway. Learned the hard way to double-check weather forecasts.
- Curious if anyone's tried using rubber washers or dampening pads under the fan mounts to cut down on vibration? Seems like it might help keep things sealed longer.
I've tried rubber washers before—not a miracle fix, but they did help reduce some of the rattling. Might be worth a shot if vibrations are your main issue... just don't expect total silence or anything.
"Might be worth a shot if vibrations are your main issue... just don't expect total silence or anything."
Yeah, rubber washers helped me a bit too, but honestly, what made the biggest difference was adding some extra bracing around the fan housing. Took a bit more effort, but vibrations dropped significantly after that.
Good call on the extra bracing. I had a similar issue with mine—rubber washers were decent, but the real improvement came from adding some foam weatherstripping around the housing edges. It absorbed vibrations surprisingly well and wasn't too tricky to install. Might be worth trying if anyone's still struggling with noise... every little bit helps, right?
