Temporary Repair to Rusted Bathtub Leak

Periodically, we've had a leak from our second floor bathtub.  Typically, the leak shows up as a stain on our dining room ceiling.  Typically, I make some measurements which show it's likely coming from around the bathtub drain, overflow and faucet.  

In the past, I have re-caulked the bathtub wall tile interface that that seemed to work for a while.   When that stopped working,  I put a silicon funnel/spout on the overflow, since I thought the seal was leaking.  I also put a silicone funnel/spout on our master bath jacuzzi.   Both of these overflow solutions worked and solved the leaking tubs.

This recent leak, did not seem to be associated with caulking, since I just re-caulked to get rid of mold.   I checked the over flow drain and the seal was fine.   Finally, I checked the rusted area by the drain. I put a small amount of water in the area and it "disappeared" without going down the drain.  For reference, I had been painting the rusted area with acrylic refrigerator paint to improve the cosmetics.

I decided to buy an epoxy repair kit.  As I poked at the rusted area, chunks came and revealed a small how about 1/4" round.  I then used a drill to wire brush the area, which made the hole bigger and revealed another gap.

Rust around drain with touch up refrigerator paint removed:

I tried the white epoxy that I bought, but it was not viscous enough to effectively fill the hole.  I then used some gray JB Weld, which is slightly more viscous to fill the hole with 3-4 layers.   Then I covered the area with the white epoxy

Taped off to apply JB Weld and white epoxy:

Repaired:  Using JB Weld and white epoxy

While the repair is noticeable and not blended in, it is sufficient structurally to allow showering, and maybe even a bath.  However, the rust will continue and therefore, the bathtub will need replacing.  We're choosing to do it earlier, before another leak occurs.   In addition, we may choose to do a full bathroom remodel since replacing a bathtub requires replumbing, and retiling the walls.

Disclosure:  I was not compensated by JB Weld for this post.

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