Below is the step by step process needed to produce a beautiful, solid wood surface that will last for generations. First acquaint yourself with the process, and then decide if you want us to build it all for you or if you want to do some of the steps. Finally use the calculator to see what it will cost.
Kiln dried wood slabs must first be re-flattened on both sides to remove any irregularities that happened during drying. Both sides are flattened to enable further processing of the slab and to ensure the finished surface can be easily installed. During the 2 sided flattening step, the thickness of the slab is commonly reduced by roughly 1/2". Want to DYI? Check out this YouTube Video.
Next rough preparation of the surface is done. This includes rough sanding for smoothness, small crack repair and edge sculpting.
Need a surface wider than the slabs we have? No problem. We specialize in gluing together bookmatched sets of live edge slabs from the same log to reach your target width. By carefully matching the natural features in the slab your surface will have a symmetric beauty. Frequently our customers say they cant even see the glue line!
It is common to find cracks, insect holes, small sections of rotted/soft wood, etc in slabs taken from large, old trees. We love to emphasize this natural character in the wood. Depending on your preference this can either be left in it's natural state or can be stabilized/enhanced with bow ties/butterflies and wood epoxy. If this applies to your surface contact us for recommendations on how to best do the enhancement and what it will cost.
$100/Bow Tie. Other Enhancements: $80/Hr. Est hours given before work begins.
Breakout the sandpaper! Your surface is cut to it's final size and the detail sanding is done. Surfaces are sanded several times at progressively finer grits up to 240 using hand tools. If you are want to be part of building your surface and save money to boot, this is a good step to consider taking over.
The last step is applying the finish. We use a variety of both water and oil-based finishes based on the color and durability requirements. For most projects we apply at least 5 coats to top/3 coats to the bottom surfaces to both seal and protect the wood for generations.