I have been cutting a lot of slabs lately and building a lot of tops. This is the first one that I have finished out of a big double-crotch Siberian elm that I milled in the spring. The top is 36″ at the narrowest and 58″ at the widest. The slab was milled 3″ thick and was flattened and finished with a hand-planed surface at 2″ thick.
For those of you that haven’t heard yet, Siberian elm is one of my favorites. The wood needs nothing added to it to make it beautiful – just a clear top coat (actually four coats of Klearvar) is all it takes. The wood for this top is a delicious medium brown with tons of visual interest, especially where the main trunk splits into three branches.
The wood slab and the steel base (built by Commercial Fabrication) are going to serve as a 42″ bar-height community table in my customers newly remodeled basement.
I often get asked, “What can I put on wood that will protect it outside?” My follow-up question is, “Do you want a finish that builds up to a film or just something that soaks in, like an oil?” If the answer is a film finish, I recommend Cetol Door & Window, from the Sikkens Proluxe line of wood finishes. It holds up better than any other outdoor finish that I have used, and every painter that I know and trust uses it too. I have found Cetol to last almost twice as long as the next class of film finishes.
In my teenage years, I tried regular ol’ Minwax polyurethane on the wood bed of my restored ’63 Chevy pickup truck, and I couldn’t believe how fast it started to peel. One St. Louis summer of constant heat and sun made it look like it had a bad sunburn with lots of dead skin.
After that, I moved on to other products like spar urethanes (Minwax also makes one of those, called Helmsman’s). Yes, it lasted longer, but not LONG. It started to look bad after a little more than a year. It didn’t totally fail all at once, but enough areas were falling apart that it didn’t really matter – it just looked bad.
In defense of these two products, the bed of a pickup truck is a tough environment. It gets direct sun, extra heat with no breeze, and the surface is horizontal, so water has a much better chance of nosing its way under the finish. It really gets no more demanding than this for a wood finish.
With yearly maintenance, the spar urethane could be kept looking reasonably good, but eventually the maintenance gave way to submission and the weather won. The boards still looked alright (nothing rotted through), but there were always spots where the finish failed and the beautiful clear-coated lumber had cracked finish and gray spots of raw wood.
It wasn’t until much later that I was introduced to the Sikkens brand name from a friend in the St. Louis Woodworkers Guild. He had great things to say about their products, and then I started noticing them being used by different painters on different jobs around town – and consistently. Nobody was using anything else, at least not anyone that I trusted, so I started using them.
Originally, Cetol only came in various forms with added stain. Some of the colors were pretty light, but none were clear. I believe the color is added to help with UV protection, but it does nothing to help color matching or achieving a clear finish. Now, with the name change to Proluxe, a colorless version is available, and it is the one that I use.
The can says that Cetol should be applied with a brush and not rolled or sprayed. I haven’t rolled it, but I have brushed and sprayed it, and both worked fine. Spraying is more difficult, and probably not recommended by the company, because the Cetol has a long working time and tends to sag if applied too liberally. That same working time is great for brushing and allows large areas to be worked and reworked to blend brush strokes. If you do try to spray it, start with a light application and allow it to settle for a second so you can get a feel for how it is going to sit down. Keeping a wet edge isn’t critical because it doesn’t even start to get tacky for a long time and the following passes will easily blend together. If you do spray the Cetol be vigilant about finding areas that start to sag or run and simply blend them in with a brush.
Cetol, like many other finishes, takes three coats to build a good protective barrier. A fourth coat will add a bit of extra protection, but isn’t required. I would opt to skip the fourth coat on the initial application and put that energy to a maintenance coat later down the road.
Regular maintenance is critical to keep the finish from failing. Keep an eye out for areas that start to crack and get another coat on as soon as they appear. If you wait too long it will be necessary to completely strip the finish and start over.
Cetol should last for several years without maintenance on vertical surfaces and even more if they are protected from the sun. Horizontal surfaces in the sun will probably last a maximum of two years before they require attention. Both of these time-span numbers are not great, but they are at least twice as long as the spar urethanes. If you jump around the internet and read about other choices or recommendations from other woodworkers, you won’t find anything that lasts longer.
Unfortunately, three years is really the maximum for an outdoor clear finish with sun exposure. Of course, if you know of a finish that lasts longer please let all of us know about it. But, do watch out because the world will beat a path to your (long-lasting, clear-coated wood) door.
A few years ago I cut a huge American Elm log into slabs and quickly sold all of them except one piece that ended up being short after hitting a few nails. The nails dulled the sawmill too much to finish the cut, so I just cut the slab off at about five feet long and salvaged what I could. All of the other slabs where long enough to make large tables while this one struggled to find a home, until I got a request for a kitchen peninsula top.
I flattened the slab on the Lucas mill and sanded it by hand since it was too wide to fit through the wide belt sander. It wasn’t until I sprayed the first coat of finish on it that I realized how nice it was and was reminded why I like American elm so much.
The slab had a great shape with a beautiful crack down the middle and the edges had tons of character too with ridges and bumps down the entire length. But, what really made it stand out and grab your attention was the figure of the wood and its chatoyance, or the way the light bounces off of the surface. The finish has great depth and changes in brightness as you walk around the piece. It reminds me of satin sheets with ridges that reflect ribbons of light. It is really something that you need to see in person.
Here are some before and after photos of the slab.
If you want to make something look older, just add some worm holes. Sounds simple enough, but there is a major difference between just poking holes in the wood and making the holes look authentic. Now that the all natural, rustic wood look is in style, even new, or at least not very old wood often benefits from more character, and I am here to show you how to really do it.
First off, let me assure you that I have a lot of experience in this field. I often build pieces that need to be “wormed up” in some regard, either to make new wood look old or to make old wood look even older. Especially on projects like beams and mantels, worm holes help add a lot of age to a piece.
Much of the wood that I use already has worm holes in it because I let the logs sit awhile outside before I mill them into lumber (sometimes even on purpose), so I have a head start, but there will still often be spots without bug holes where the wood needs a little extra love, like in the following video:
To get things started, it helps to first look at truly worm-eaten wood. There are consistencies even in what looks to be very inconsistent patterns. Here are a few principles that hold up in most wormy wood:
1.) Hole sizes vary: Even similar-sized holes are not the same. Your method for creating holes should easily produce random results.
2.) Worms tend to focus their efforts: Holes will usually have an area of focus, with more holes in the center of an infected area fading out to fewer holes.
3.) Not all holes are perpendicular to the surface: While most holes are just that – holes, many are oblong and some are more like trails.
4.) The bugs that make the worm holes often enter around defects in the wood: Soft or punky wood, spalted wood, cracks, and sapwood are all areas that will focus worm activity. Good, strong, solid heartwood is the last area to be bug infested.
5.) Small holes outnumber the big ones: Older wood that has been attacked by multiple insects will have lots of tiny holes (1/16′ diameter), some medium-sized holes (1/8″ diameter), and just a few big holes (up to 1/4″ diameter).
Here are some photos of authentic worm holes. If you can copy any these patterns you will be off to a good start.
Here are some of my tricks for achieving realistic results:
Small holes. You’ll be tempted to use a drill bit for the smallest holes, but it isn’t the best choice. Tiny drill bits break easy and the size is too consistent. Plus, they pull out wood fibers that make the edge of the holes fuzzy. Instead use a nail or a scratch awl sharpened to a long fine point. A scratch awl is the best choice because it can be used without a hammer and produces speedy results. The long point will make different sized holes depending on how deep it is pushed into the wood. Push the scratch awl in the wood at different angles and different depths.
- Large holes. Use a twist drill bit for the larger holes. Be sure to drill deep enough that you can’t see the bottom of the holes and to vary the drill angle. Put the bigger holes in the softer wood. Sapwood, punky wood and areas around defects are a good place to start. Mix up the sizes in the 1/8-3/16″ range for a more natural look.
- Oblong holes. Some of the larger holes tend look like small jelly beans. Drill in fairly deep and then use the side of the drill bit to cut a short trail. The result is similar to two holes drilled right next to each other.
- Trails. Trails are often left just under the bark in bug infested logs and sometimes inside the log. Use a twist drill bit about 1/8-3/16″ in diameter and drag the bit in different lengths of crooked lines. Be sure to make some of the areas have more depth. Think of the trail as a river with shallow areas and deeper pools. Trails can have one, both or none of the ends finishing in a hole. Mix it up and have a few ends disappear into holes made with the same drill bit.
One of the most important things to remember when making worm holes or using any other techniques to age wood is to really go for it. You won’t destroy a piece of furniture by adding a few more holes or dents, and you can only miss by doing too little to the surface.
I often see furniture, especially mass-produced furniture, that will have some sort of distressing that looks like it was just phoned in. Usually, someone quickly takes a chain to the surface or pokes a few holes and calls it a day. Don’t do that. Pay attention to Mother Nature’s work and try to duplicate it. And, most importantly, have fun doing it.
Sometimes in life you need a tool that you don’t own, don’t have handy or don’t have any idea where it is. I have this problem a lot and it is usually closely related to the fact that I don’t put my tools back as I use them. I subscribe to the “leave it close to where it is most likely to be used next” method of organization, which somehow, always leaves a tool a long way from where it is actually needed next.
I had this same problem when setting up to spray a two-part conversion varnish finish. I had all of my supplies, but no empty cottage cheese containers to work out my ratios. You don’t have to use cottage cheese containers, but I always had some handy and had used them consistently after I figured out how high the finish should be in the container and how much catalyst to add. The mixture is actually pretty simple–one batch of finish, plus 10% catalyst.
One thing I never liked about my cottage cheese container system was that I had worked out how much I needed for a full pot on my spray gun, but beyond that it wasn’t easily adjustable. If I only needed a little finish, I didn’t have a system for figuring that out. A scale would have worked great, or even measuring cups would have been nice. Heck, anything related in any way to weights and measures would have helped. But I am never that prepared.
So, there I was, looking around the shop for empty containers and finding none, but I had a revelation. One of the containers I did find had some old finish in it, and I could see the level of the finish inside the container by looking through the white plastic, and I realized that I was just inches away from having a measuring cup, except my cup didn’t have any measurements on it. No good – right? Actually, not so bad. I could make up my own measuring system (inspired by Bill Cosby and his story about Noah, I call them cubits) and mark them on the side, if I could just find an empty container.
Then the wandering begins, looking around the shop for something that might work. Then the digging begins, as I move everything in my finishing area to try and uncover an empty container. Then the cussing begins as I still find nothing to mix the finish in before I put it in my spray cup. Then… Wait! Hold on a minute! My spray cup. That is the one and only, now very clean and very empty container in the shop, just waiting to have something put in it.
Now, I am really on to something, but I can’t see through the aluminum cup to mark my cubits on the outside. If only the cup was clear. I needed a way to see how much was in the cup without being able to see through the cup. I needed some sort of stick, something that you dip in fluids (I don’t know what I would call that thing). And, you know what would be even more awesome? If whatever I used could always be found and be something that I would never have to worry about putting away. Yes, an actual stick of wood as a dipstick. Genius.
But wait, it gets even better. Since the stick didn’t have any measurements on it, I could make my own and make a different one for each batch. I could make any adjustments I needed . All I had to do was transfer my cubit measuring system to the stick, and I was in business.
I labored a bit over my cubits and how long they would be. They couldn’t be an inch because that name was already taken. Same with a half an inch and a quarter of an inch. Any measuring system I was going to use was based on an inch and that’s just not how cubits work. Everyone knows that no one knows how big a cubit really is, so it couldn’t be based on anything that already exists. The good news for the cubits of the world is that I still can’t tell you how long they are, but luckily it doesn’t matter.
The first step was to fill up my cup with finish. With the new fancy cubit ratio measuring system it didn’t matter how much I used, just as long as it was enough to do the job. Then I walked less than two feet and grabbed the nearest, short scrap of clean wood and dipped it in the finish. The highest point on the stick to get wet was now the new cubit.
I marked the high point (cubit) on the stick with a pencil and then marked a second point 10% higher to indicate how much catalyst to add. There are two ways to figure where the 10% mark goes. The most accurate way is just to measure the length of your cubit, say 5 inches and multiply by .10, which equals .5 or 1/2″. I like this method because it’s accurate and uses just a tape measure and simple math, but it isn’t as simple as it could be. My new and improved method (though admittedly slightly less accurate) is to, by eye, divide my cubit in half, then in half again, and then in half again. At that point I have a mark that is about 12.5% of the full cubit. Then again by eye I deduct a few percentage points so I am in the 10% range, and then transfer that mark to the top side of the cubit line. It takes no tape measure and no math.
Here’s a quick rundown of the process:
The new and improved, super-simplified, cubit measuring system works for any fluid mixing in a straight-sided container and is accurate (as long as you aren’t blind). It is simple simon and knocks the whole process down to a stick and a pencil. And, if I can’t find those two things buried in the shop somewhere, then I am really in trouble.
All of the woodworkers I know like the woodworking part, but most of them dislike the finishing part. They have a great time using their tools to craft something beautiful and useful and then get paralyzed when it is time to wrap it up. They want it to come out perfect, or at least really good, and are sure that they are going to mess it up. Usually, they have tried applying a finish with a brush, or a roller, or a cloth, or all of the above and more, and the results were never great. It is possible to get a good finish with a brush or any of the above, but it isn’t easy and usually comes up short of perfection.
In the quest for a better finish, many woodworkers ask me about spray guns and spraying in general. They are looking for a better finish, a finish that is easier to apply, and a finish that makes their hard work shine. Their reasons for not already owning a spray gun are numerous, but when I am asked if they should purchase a spray gun, my answer is always a loud and excited, “YES!”, followed by, “What in heck are you waiting for?”
On my list of essential woodworking tools, a spray system ranks near the top, only after a table saw, jointer, and planer (and, logically I suppose, after sandpaper). I use a spray gun on nearly every project and for a multitude of reasons, with the main reasons being quality of finish, speed, speed and speed. Quality of finish is self explanatory, but the triple speed thing may need a bit more description.
With a spray gun, the application is fast (speed #1). From spraying stain to applying the last coat of finish, the spray gun can move some material quickly. There is no faster way to get finish from the can to a project, short of just dumping it on. If the gun is working well and the finish is flowing nicely, I can often put down finish as fast as I can move.
The spray gun also allows me to use fast-drying finishes (speed #2) like lacquer or conversion varnishes, which are impossible to apply any other way. With lacquer products, the finish is often hard enough to sand and be recoated in just 15 to 30 minutes, compared to a full day with oil-based polyurethane. Lacquer dries so fast, that I often spray parts just before heading to an install, throw them in the bed of my truck, and they are ready to install by the time I get to the job site. It can’t get much faster than that.
The best part for me, not being the most fastidious of woodworkers, is the time it takes to prep the spray area when using lacquers (speed #3). Besides covering areas from potential overspray, there is no prep required. I usually spray right next to my table saw or anywhere that I have room in the shop and do nothing about the dust. I just blow off the piece I am about to spray and get on with it. The finish dries so fast that dust doesn’t have time to get in it. I literally do nothing before I spray, even if I am standing in a pile of sawdust (the piece I am spraying is on sawhorses and not in the pile of dust, of course). I would never even think of working like this using something like an oil-based polyurethane, which seems to pull in dust from everywhere. (Quick note: I do use the gun to spray slow-drying finishes too, but the spray area needs to be clean and dust free, and I would prefer to skip that here in the speed, speed, speed section.)
Besides the above four advantages, I am often asked additional questions when it comes to spraying, but I must warn you, the answer to all of them is still, “Buy a spray gun!” Here are some of the most common questions:
- Can I spray ________ with it? Yes, YES, yes, yes and YES! You can spray any liquid finish by changing its viscosity and/or your spray tips, if needed. It is no different from a brush – a spray gun is just a vehicle to move finish from the can to the project.
- I don’t have anywhere I can spray inside. Can I spray outside? I think outside is the best. Spraying outside requires no exhaust fans and usually provides ample space to work. Plus, it is just nice to be outdoors. I often move outside to finish large projects, or if I am out of room in the shop and need to spread things out. The best outdoor spot is a garage (with the door open), which has good ventilation, controlled wind, and a shield from the sun – a lot like an actual paint booth.
- What about the fumes when I spray indoors? Yes, there are fumes when spraying solvent finishes, but they can be dealt with quickly and easily. First, spray near a window with a fan in it (instant paint booth). Second, wear a mask while spraying. Third, don’t spray when your wife is home.
- Won’t the overspray get on everything? Sort of. The spray gun will shoot finish beyond the workpiece (overspray), but most of it will land in the form of dust. Fast drying finishes like lacquers dry almost instantly in the air, so only overspray close to the workpiece is wet and sticky. Even the overspray on the floor directly beneath the sawhorses just sweeps up.
- Isn’t a spray gun a pain to clean-up? No. If you stick to solvent-based finishes, like lacquer, that dissolve with lacquer thinner you only need to clean-up when the gun isn’t working right and then only by soaking the parts in lacquer thinner. If I am spraying lacquer, I treat the gun just like a can and leave the finish in it until the next time I spray. If you are using finishes that aren’t soluble after they dry you can’t be so cavalier, but it still isn’t a big deal. Often, it is only a matter of spraying the solvent through the gun until it is clean.
After I berate someone for not already owning a spray gun and then tell them over and over again to buy one, the next question they ask is usually, “Which one should I buy?” My answer is simple, “Not a cheap one.” I have used several different high-quality, name-brand HVLP spray systems, and all of them did a good job. There are, of course, subtle differences in the way the guns work and some may be better than others, but none of the higher-priced systems will be a bad purchase. I have personally used HVLP systems from Fuji, Apollo and Graco, and all of them give similar results. At the same time, it is worth noting that I have used cheap no-name guns, and they were painful to use. The spray was splotchy and the guns would only put down a wet finish in the very center of the fan pattern compared to the entire width of the fan pattern from a good gun.
When selecting an HVLP gun there are lots of choices, and again, as long as you don’t buy a junk gun they are mostly just different, and not necessarily bad. I currently use an older HVLP system made by Graco. It has a turbine and a small compressor that pressurizes the 2-quart pressure pot for the gun. I use a pressure pot because it holds more finish, so I can refill less often and keep moving. Plus, with the pressure pot system the gun profile is small to fit into tight spots. For most uses and especially for those of you that don’t even own a gun, one without a pressure pot is fine, leaving you only to decide on two items, the type of gun (bottom-feed or gravity-feed) and the air delivery system (air compressor or turbine).
As far as the guns go, I prefer the bottom-feed gun because it holds more finish, and since it is the type of gun I started with, it just feels right. At the same time, I know several people who use gravity-feed guns with no complaints. They like that the gun is a little lighter and fits in smaller spaces, and they don’t mind refilling as often. Between the two there really is no bad choice.
The air delivery system is the other area to focus on when deciding which system to purchase. The guns can either be powered by an air compressor or a turbine, and you get to choose which makes the most sense for you. Again, neither is wrong or bad, just different. First off, do you own a large compressor (5 hp, 50-gallon tank)? If you do, and you don’t need to be portable, you can save some money and just buy a gun. If you don’t, I wouldn’t recommend buying a big compressor just to spray. I would spend the compressor money on a turbine unit because it is very portable. I know I often take my gun with me to the job site or just outside, and I appreciate not having to lug around a giant compressor just to spray.
Here are the key decision points to address when purchasing your new system:
- Do you already own a large compressor and don’t need to be portable? If you already own a large compressor you can save money by only purchasing a compressed air gun. Don’t buy a big compressor just to spray, spend the money on the more portable turbine system.
- Would you like to use your spray gun outside of the shop, maybe at the job site or at your house? Turbine systems are the lightest and most portable. If you need to take your spray gun with you, pick a turbine. If you are only spraying in the shop, either a turbine or compressed air system will work.
- Are your jobs big? Bigger jobs (full kitchens, for example) require more material and may benefit from a system that can hold more finish. If you are spraying very often or are consistently spraying large jobs, think about a system with a pressure pot. Otherwise, stick with a gravity-feed gun or bottom-feed gun. Note that even large jobs can be sprayed without a pressure pot, but will require more refills.
- Do you have extra money? Here’s your chance to spend it. None of the good spray guns are inexpensive. Expect to pay $800-$1,000 or more for a complete turbine system. And, remember, don’t buy a cheap one.
If you have been thinking about buying a spray gun, stop! There is no reason (except for money) to think about it anymore. Start living your woodworking dream and buy one. No one, and I mean no one, has ever been unhappy knowing that they had a good spray gun to use whenever they needed it. You will use it so much more often than you think, and, though a good spray system is expensive, it may make you actually enjoy finishing.
If you have any concerns about using or purchasing a spray gun, let me know below in the comments section. I am certain that I can allay any of your fears and maybe even answer a question or two.
One of the best finishing tips I’ve ever picked up came from an episode of “This Old House”. Norm and Tommy were building some cabinets for a house, and they were spraying a lot of plywood. They showed how they used a razor as a scraper to knock off the nubs between finish coats. It looked simple, so I gave it a go, and I haven’t looked back since.
Let me first start by saying that the razor isn’t perfect. It is flat and straight, so it doesn’t work for profiled edges or rustic, wavy surfaces, but it is great for big, open flat spots. I use it most often on sheets of plywood, but also use it on the flat spots of doors, including the stiles and rails.
The beauty of the razor is the simplicity and speed. With one razor blade, I can quickly smooth a surface between coats on a job that would eat up several sheets of sandpaper. The big difference is that the razor doesn’t clog up with finish like sandpaper does, it just scrapes off the high spots. This is especially helpful when I am trying to finish a job in just one day (which is usually the case). As long as the finish is set up enough to handle, I can start scraping with a razor and never have to stop. In the same scenario with sandpaper, it would clog almost immediately causing me to use more sandpaper and not get consistent results. The clogged sandpaper also tends to drop off little boogers of coagulated finish that stick to the surface. That never happens with a razor.
Using the razor is simple. Hold it up nearly vertical to the surface, lean the top into the cut and pull or push the direction you want to go. It works just like a cabinet scraper, only on a smaller scale, and it doesn’t need to be sharpened. When the razor is dull, just grab another one and move on. I often flip the blade around and cut the opposite direction to make the edge last even longer. If it feels like it isn’t cutting, flip it around. If it still isn’t cutting, just grab another one and get back to work.
Quick tips for using a razor:
- Make sure the finish is dry before scraping.
- Make sure runs are super dry before scraping. The finish should scrape off in shallow layers, not rub off in big chunks.
- Always use a new razor. Old razors can have nicks that scratch the finish.
- Use a razor on flat surfaces. Razors do not work on profiled edges.
- Watch the sharp corners. The corners of the razor can easily scratch the finish.
- Use a light pressure to start. Apply more pressure as you get more comfortable.
If you are going to be doing a lot of scraping, I highly recommend wearing gloves or putting tape on the top of the blade to serve as a handle. The blade gets hots and starts to dig into your hand during heavy use, so it is best to make it as comfortable as possible. There are plastic blade holders commonly available as well. They work fine, but they got lost easily. It seems like I can always find the blades (mostly because they came in a jumbo pack), but I can never find the holders.
As I mentioned, the razor is great for flat surfaces, even curved, flat surfaces (what?). Yep, that’s right, the ol’ curved flat surface, like the belly of an arch. The razor will work on a surface like this, as long as it can sit flat. You can still follow the curve by changing the angle of the blade and quickly scrape the surface.
The razor is not a good choice for profiled edges. First off, it often can’t reach where it is needed, and secondly, there is a great risk that one false move might destroy an edge. In this case, sandpaper or a Scotchbrite pad is the poison to pick.
I use the razor between coats of sanding sealer and even topcoats, when necessary. It makes for a speedy job and a quality one at that. The razor takes off only the highest finish, which is usually just dust nibs and other loosely clinging items (like the legs of flying insects). And, with a little extra pressure a razor will dig in deeper to help remove runs and other problems, like finger prints, smudges, etc.
When you use a razor for scraping a finish, watch the edges of the razor and your pressure. The edges of the razor are sharp and can easily leave an errant scratch. Use a light touch, so if you bump the edge into something it won’t plow a line through it. The lighter pressure also ensures that you don’t take off any more than the imperfections. Only apply more pressure after you get the hang of it and when you really need it.
Lastly, make sure to use only new razors. A razor that has even just one ding in it will scratch up the surface, and the scratches won’t show until the next coat is sprayed. Don’t be a cheap skate and try to stretch the blades you have. Buy a pack of 100 and rest easy knowing that you will use all of them, either for scraping or in a knife.
Using a razor on your newly applied finish will seem scary at first. Go slow, use light pressure and be careful. In just a few minutes you will get used to the feel of it. As you work, use your hand to feel the progress along the way, by rubbing the surface to feel for imperfections. Your hand will tell you what you’ve missed and where you need to work a little more. Give it a try, and after just one swipe of the razor, I think you will be hooked.