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Help with applying Varathane Stain+Poly

5.3K views 5 replies 4 participants last post by  DrRobert  
#1 · (Edited)
I purchased a new, unfinished luan door, sanded it well with #220, and applied one coat of water based Varathane clear polyurethane and then decided I wanted it darker.

I then purchase oil based walnut Varathane Stain+Poly (Home Depot didn't have water based). I lightly sanded the door with #400 and used compressed air and my hand to get rid of the sanding dust. Brought the door into my garage and laid it flat on stands.

I thoroghly stirred the Stain+Poly and used a new 3" Wooster Pro 100% nylon " soft" square wall & trim brush (meaning not an angled sash brush) to apply the Stain+Poly.

The outdoor temp was in the low 80s but it may have been warmer in my garage. Humidity was low as I'm in northern California.

I applied about a14" band of product across the top face of the door and then immediately moved down to apply the second band, with strokes starting on bare wood and moving up into the existing coated strip.

It was obvious as I was applying the second band of product across the door that the point of overlap from the bottom of the upper band and the top of the lower band was darker, from the stacking of two layers. I immediately attempted to brush this out without success, and that attempt only added brush "lift" marks to the problem set. All very frustrating.

I contacted Varathane support and they were of ZERO help.

Do any of you have advice on how to brush apply this product to a large surface like a door, is it that just not going to work?

I thought perhaps I should order some water-based Stain+Poly and try that, but I don't want to waste time and $ if the result is going to be no better.

Any advise you can offer will be greatly appreciated!
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Discussion starter · #3 ·
It's just very difficult to apply a varnish stain and get it uniform, especially with a brush. It really needed to be sprayed by someone experienced with a sprayer. It's also not a very good idea to put an oil based finish over a water based finish.

From where you are the easiest fix would be to replace the door and use stain first the next time. Being a birch door you should use a wood conditioner prior to stain. This allows the stain to color the door more unform. The door you have could be chemically stripped and refinished but I think by the time you bought remover and solvents to strip the door you could replace the door. Save yourself the work.
Steve, thanks for your input. Unfortunately, that was pretty much the answer I expected. I had a gut feeling I'd regret trying to use that product on such a large surface.

I'll sand the jacked-up side of the door and just stick with the clear water-based poly. I have the equipment to spray, but not the environment.