My patched areas, once primed and painted, are noticeably more "fragile" than original painted drywall - e.g. I can dent them with fingernails, the same way you can dent a chalk stick with fingernails.
(I’m not talking about a movement of the whole patch if i apply palm pressure — the patch is held firmly with screws in furring and/or studs. I’m talking about the repaired area not handling point pressure well. e.g. a ballpoint pen would leave a scratch rather than roll).
I’m wondering if that’s just par for the course with drywall repairs in general, or if there’s something I’m missing…
Here’s how i generally proceed to fix large holes:
add pieces of furring to provide a backing (or do california patch)
if any, prefill gaps with quickset joint compound (aka “hot mud”)
after it’s hardened, scrape excess bits (no sanding)
tape joints with lightweight all-purpose compound. let dry.
apply second coat to even out depressions or ridges, with lightweight all purpose. let dry
apply “skim coat” — very light coat, to feather out ridges, and remove bubbles, with lightweight all purpose. let dry.
sand until smooth to the touch. if there are pinholes, i will typically do local touchups (possibly that could be where i go wrong)
apply paint primer (specifically formulated for drywall) with a 10mm roller. let dry.
apply two coats of latex eggshell paint with 10mm roller. wait at least product recommended duration between coats.
give it 1 week to “cure”
After all this, i find the patched wall areas look good, but they are definitely “softer” than the other painted areas.