- First, I found the stain and polyurethane that was used by painters 10 years ago. The stain still seemed good, but the the spar urethane had gelled and no longer usable.
- I had purchased a battery operated oscillating tool for another project. I decided I needed an orbital sander in addition and purchased one.
- I tested the sanders and spar urethane on some outdoor furniture over the summer using a brush. It seemed to work well.
- I decided to wait for fall weather temperatures before doing the front door.
- In the meantime, I checked the internet for recommendations on staining and applying polyurethane.
- The key learning was that the stain should be applied with with a cloth or stain pad. A brush had a tendency to cause brush marks or dark areas.
- A second key learning was to do step sanding: initial 80 grit, 120 grit, final 220 grit, before applying stain.
- Day 1- Remove hardware and sand all the flat sections. Replace hardware at end of day.
- Day 2 - No need to remover hardware. Sand curved and recessed panel areas.
- Day 3 - Remove hardware and oil base stain. Clean dried stain areas lightly with water and sand any raised grain with 220 grit. Replace hardware. Allow stain to cure overnight.
- Day 4 - Remover hardware and put 5 thin layers of water based spar urethane, semi gloss. Allow 30 minutes minimum between layers. Reapply hardware. Wait one extra day to attach the kickplate.
This is not financial, wood staining, nor door maintenance advice. Please consult a professional advisor.
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