Time and machine management

This was definitely a project that took much longer than we anticipated, much longer than it should have, with pitfalls that could have been avoided. But we were anxious to start. And had no idea what we were doing.

Each machine had upsides and downsides-- little quirks that we'll know how to better manage the next time we tackle a project like this (Ha!).

The palm sander.
It's the best $30 investment we've ever made and I love it. Since it didn't make the swirls that the edger did, it was perfect for the lighter edging, and it's smaller size and lighter weight made it great for reaching places the sander couldn't or tackling angled boards.

It's my hero.

The Best Investment runner-up award goes to the shop vac WITH WHEELS. Put a long extension cord on it, and it follows you around the house while you hunch over to get all those pesky little dust particles.

I've heard a lot of horror stories about the amount of dust that this project creates, but I don't think I was ready. I wore a paper mask, but I still could have built a new bedroom suite out of what ended up in my nose, throat and mouth. I also tried to wear goggles, but they just fogged up with my mask-redirected breath and the sawdust in the air. I tackled the stuff that required putting my face right up to the floor since I don't wear contacts. Adam does, and I can only imagine how painful that would have been...

Having not expected to use the SquarBuff, we didn't do any research. By the end of the first day, my arms were killing me and I could hardly control the machine. It weighs as much as I do, and never wanted to go the direction I was asking it to. We later discovered that the buffer pads get smushed in one or other corner and proceed to pull that direction. Flipping over the pad until it's in the right position, and frequently changing pads, giving them time to refluff, all made a huge difference in control.

Mostly, though, it just took a long time. If we had been thinking, we'd have reserved the equipment, and made a list of everything that needed to happen to each room. We'd have checked to make sure we had some of each grit-- had EXTRA of each, since you can return what you don't use. We'd have worked in shorter spurts where possible. It takes such a toll on your body, that you stop using time very effectively. We'd have tested the floor finish and cleaned the wax. We'd have been more careful with the edger's swirling.

We probably would have risked losing some board to a diagonal pass with the drum sander. It would have saved a lot of hands-and-knees work and a lot of obsessing over how to deal with the chatter-- we probably wouldn't have eliminated it, since our floors are too lose to have secured them all, but it might have reduced it.

We wish we'd known sooner that the weekend special begins Friday night, not Saturday morning.

I keep thinking, "I am NEVER doing this again." And then I go through all the "wish I'd known"s in my head and I think it would be much better next time around. We won't be able to live in this house forever-- there's no room to grow, and we plan to do some more growing...But with both of us working in education and our love of older homes, the chances of us affording a totally renovated house any time in the future are slim to none. So I guess this is our tester house; we've got the time to make mistakes and got enough of a deal that we're allowed to screw up and still come out ok...

Lotsa lotsa sandpaper

I knew we'd go through a lot of sandpaper, but I had absolutely no idea it would be like this.

I'm pretty sure that's not even complete. And there's an awful lot of little 5 inch discs that are hidden under there...

For the middle of the rooms, we first tried sanding with the SquarBuff, but it just didn't have the muscle. That's when we picked up the drum sander to cut through the finish. Adam worked this machine, so he may have some things to add later, but I can tell you what I saw. The 24 grit paper really cut through, but the finish gummed it up pretty quickly. The top layer was melting and reconstituting on the belt in hard, shiny discs. This was another situation in which no one in town sold belts to fit, the rental store had closed for the weekend, so Adam was scraping what we thought was melted varnish off the belts to reuse them.

Then we hit the middle of rooms with 36 on the buffer. This was the end of last weekend.

This weekend, we picked up the edger and Adam went through edging all the rooms with 20 and 36 grit paper, taking care to level out the lip left by the drum sander. Again, we were flying through 20 grit paper, so I hit up the rental before they closed to get more paper. (BTW, the big boxes DO carry paper for the edgers and the buffers, just not screen) I described what was happening and the uy at the store told me that what was gumming up the discs was wax.

Tip number 2: Be sure to check what kind of finish it is. If it's wax, buy the special wax removing cleaner and clean it off. The rougher grit paper is the most expensive, and changing it frequently is a time waster. Just wasteful all around.

Then we hit each room with the palm sander at 40 grit to take care of any uneven boards. We decided not to cut across diagonally so as to save as much board as possible. One room's boards were all angled, so this one had to be done one board at a time by hand.

As for that dip in the floor, we sanded with 36 on the edger and finished with 40 on the palm. It didn't totally get rid of the lip or raised grain, but it did ok and we still ahve intact floor boards.

Then I buffed with 36 yet again, and then hit it with 60. At this point, I realized that the buffer wasn't really eliminating the swirling left by the edger. Adam had to go back to our rental house, so I stuck around over the holiday and wrapped up the round of 60 and took our little palm sander, with 40 grit discs and went around the edges by hand, taking out all the swirling. I also realized that the tack board (or possibly our removal of the tack board) had left a pretty deep scratch in the floor in a perfectly straight line. I sanded this out as much as possible.

Tip number 3: Don't just assume the swirls will sand out. They're a real bitch to get out, and if you can avoid them, do. After we realized that they were going to be a problem, Adam was able to really use the 36 to carefully remove the 20's big whirls and it went much, much faster in those rooms.

We also noticed that the drum sander had left a lot of little ripples, chatter, in the floors that the buffer wasn't getting rid of. I'm pretty sure this is due to the vibrating boards, as Adam had a pretty smooth hand with the drum sander. The shellac disguises a lot of this, but we'll probably see it in the shine of the poly. We'll try a satin finish to get a more waxed look and to dampen the high sheen.

Tip number 4: If you can secure loose boards, by all means do it. If you can get away with just screening and reapplying the same finish that was on before, do it.

Adam came back on Christmas day and we hit the middle of the rooms with 80 and did the edges with 80 on the palm sander.

On Wednesday morning, we returned the edger and they gave us some more screens and a few extra hours. Adam screened all the rooms, while I made a final pass at making sure the swirls were gone. Then we realized we never got rid of the drum sander lip in the kitchen, so I did my best with the palm at 40.

Then we celebrated with burgers and beer.

After lunch, we hit the edges with 120 on the palm sander and I used a carbide pull scraper to get into the corners and around the outlets in our floor.

We vacuumed, tested a few shellacs and called it a day.

Here's the breakdown on sandpaper:

Edging:

For the kitchen, about 8 discs of 20 grit @ $1.50ea= $12

Rest of house,
19- 7"discs of 20 @ $1.50 = $28.50
10- 7"discs of 36 @ $0.82 = $8.20 (we also bought a 3pack of 36 at the big box for about $5)
100- 5"discs of 40 for palm sander. 2 packs of 50 @ $17 = $34
50- 5"discs of 80 for palm sander. 1 pack of 50 @ $17 = $17
15- 5"discs of 120 for palm sander. 1 pack of 15 @ $7 = $7

Middle:

6- belts of 24 for drum sander @ $7 = $42
2- sheets 20 for buffer @ $6 = $12
10- sheets 36 for buffer @ $4.14 = $41.40
5- sheets 60 for buffer @ $3 = $15
4- sheets 60 for buffer @ $5.25 = $21 (from the big box-- always cheaper at the rental!!)
7- sheets 80 for buffer @ $2.50 = $17.50
4- screens 100 for buffer @ $7.50 = $30 (they only charged us for one since they forgot them. I love those guys!!)
5- buffer pads from rental @ $6.50 = $32.50
3- buffer pads from big box @ $7.50 = $22.50

Grand total in sandpaper:

$333.60

plus rental fees ($175)

$508.60

The continued rental saga.

My previous post from last weekend details the first few days of our equipment rental epic.

Well, this weekend we used our noodles and reserved the equipment we needed: an edger and the square buff. We picked them up on Friday evening and returned them on Wednesday morning.

Tip number 1: As I mentioned before, this is something that I cannot believe nobody told me-- local rental stores don't charge for the days they're not open. So I highly recommend, if you can stand sacrificing your holiday time, renting over weekends and especially Monday holidays that get you that extra bit of time. Our place does a "Weekend Special" that's a 2 for 1-- pick it up after 4pm on Friday and return it before 8am on Monday and it's yours for the price of one day.

For the edger and buffer, 5 days rental (they were closed Sunday, Monday and Tuesday)., we paid $68 in rental fees-- that's one day each at $39 and $29. A steal!! On Saturday afternoon, we realized that they forgot to give us sanding screen for the final step, and no one in town carries it other than rental stores, so they had pity on us Wednesday morning-- they gave us a few screens and a few extra hours at no charge to finish up. We're trying to come up with more things to rent just because they're so nice to us. I think they like to laugh at us when we leave, and I'm happy to provide entertainment, if that's the kind of deal we get.

Rental fees breakdown:

Edger for one day mid-week to do the kitchen: $29
Drum sander for weekend special (Saturday to Monday): $39
SquarBuff weekend special (Saturday to Monday): $39
SquarBuff weekend and holiday special (Friday to Wednesday): $39
Edger weekend and holiday special (Friday to Wednesday): $29

Equipment rental grand total:
$175

Mo floors, mo sanding.

When researching DIY floor refinishing, I came across a few repeating bits of info-- don't let the drum sander sit, keep it moving...work from a halfway point in the middle of the room...if scared of the drum, use the orbital...wait for each coat to fully dry before putting on another...sand at a diagonal if you need to level the floors... I wanted to know how much this would cost (I'm frugal!), how long this would take. I wanted specifics!

Now, I know every floor has its own individual problems. For example, some of our rooms have been refinished once or twice, then covered with carpet for the better part of 50+ years. Others have been mostly exposed to wear and tear AND refinished a few more times. In one of the previously carpeted rooms, the floor is like this:

Still a little space to work with before we hit tongue, but still not enough to fool around with. However, only a few inches away, we move to another room that's been hit a little harder and dips down quite precariously:

I wanted to know how to sand these floors aggressively enough to get the finish off, but delicately enough to not hit tongue, but aggressively enough to smooth out the ridge and smooth up the grain that's been raised by all the foot traffic.

I also have to admit that this was a much bigger endeavor than I think either of us prepared for. Mainly, it just took way longer than we had hoped, and took a much greater toll on our bodies than we realized it would, which limited our working hours.

Anyway, the following posts will detail the big Xmas present to ourselves.

(A quick reminder that this is about 1200 ft2 of heart pine flooring, with some of the black mastic still on the kitchen floor. A pro quoted about $3800 to sand, stain, and poly, and patch the 2 floor furnaces with what I assumed was newer heart pine, as he didn't specify antique. We received estimates for antique that would have run to more than $1000 for just the wood-- then we'd have to patch them, and here is where we recognized our limitations. We've decided not to patch them at this time, but rather to buy antique grates, or have custom reproductions made. At the very worst, this will cost several hundred dollars, but we won't run the risk of making a $1000 mistake if it looks bad. One furnace is in a very prominent and visible area, so we're being extra careful.)

The weekend update

I am henpecking this post due to the fact that all the knuckles in my right hand are swollen to twice their original size after spending all weekend on the floors. My back and entire left side are also a bit of a mess. Just goes to show how out of shape I am.

These are the culprits.


And this is the fiasco.

Earlier in the week, Adam spent the better part of a day on the kitchen floor edging. It took so much time because it had all that crazy black stuff still clinging to a good portion of the floor. We then both got up bright and early on Saturday morning and made the trip down to our local equipment rental. Turns out they had already rented the edger. So they talked us into the square buffer under the assumption that it might do the edges and corners as well. So we made our way to the house and got to work. But the buffer simply lacked the power to strip the varnish. Back to the rental store.

This time we got the drum sander and a bunch of rough grit to do just the first pass on the floors; we still planned to use the buffer for edges and the more refined passes. The drum sander worked like a charm and on we went. I wrapped up the 36 grit passes in the kitchen while Adam took the drum sander to the rest of the house. Then I started following behind him to edge. That's when we discovered that the buffer doesn't have enough weight behind it at the front of the machine to do edges. Also worried that we were going to run out of belts for the drum sander. Rental store was closed. Back to the hardware store. Returned with 60 and 40 grit paper for the 5" palm sander. The 40 seemed to do an ok, if slow, job on the edges, so a trip to the big box store for a jumbo pack of 40 grit discs, gatorade, shop vac bags, the prospect of belts that fit the big sander, and beer. No belts that fit.

That process proved such slow-going that we stopped and reevaluated our strategy to get the most effective use of time and money. We were going to go ahead and do the rooms with the buffer up to 80 grit, return everything Monday; rent the edger and buffer again later in the week, edge, feathering into the rest of the floors, up to 100, and then screen everything with the buffer. But then we noticed how deep the lip is from the drum sander along the edge and decided it might be best to do everything as prescribed. This wasted much time.

At any rate, there were more trips to the store, more hemming and hawing over what to do, contemplation of trouble spots, and finally, we ended up doing the middle of all rooms up to 36 grit. We'll be edging and completing the sanding part of this ridiculousness next weekend. Hopefully.

Here's where we ended:


We also sanded the kitchen up to 80, and did parts of the edge to 120 so we could test some shellacs, wood bleaches, and stains. The gigantic water stain, as well as the super thin section of flooring in the dining room, and other sundry quandries are best saved for a later post, as is the entire issue of shellac...

Best part? When I returned the equipment this morning, I found out where the edger had been all weekend: at my realtor's house.

Does it get any better than this?

Adam got started with the edger, and I am just so pleased with the way this is turning out. I'm sure I've probably just jinxed the whole project, but seriously...considering the way this entry looked not so long ago, with its 3/4" worth of ugly flooring and that horrible black mastic-- I'm thrilled!

Its not all good news. There was a thin black strip of linoleum that went around the room as part of a border. My understanding is that this stuff was heated up to adhere to the floor. It looks like maybe that particular little strip burned the floor a bit during application:
But you know what? I can't even be bothered by that. At the very worst, we'll put a dark stain on this room only-- it does look like the POs may have replaced some boards with oak strip and there's definitely some water damage on the other side of the room, as well as some slightly more prominent burn marks where the fridge will sit. I just don't want them stained so dark that the beautiful grain-- the reason we went through all this and didn't just put down a new floor-- is hidden. But I'm certainly ok with rustic. In fact, I'm ecstatic for rustic. I was so ready to throw in the towel with these floors about half a dozen times through this whole process. Adam kept me moving, though. And now no one's happier about this than I am.

And on another kitchen note...Ta-da!
Upper cabinets! They look better in person. And the two on the right aren't fully installed. We'll have to shim out the one on the far right to bring it even with the others and to compensate for the extra space created by replacing the plaster with drywall. The black and red stuff on the solid masonry wall is old backsplash mastic, soon to be covered up by...this is yet to be decided, actually...