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Post #745062 by Scaramouch on Wed, Jun 17, 2015 7:21 AM

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Thanks so much for the nice comments, everyone. It's great to be able to share it with some tiki experts and got positive feedback :)

To answer a couple of questions:

  1. All the trim carving was done with a trim router and a straight bit. This one, to be precise:

http://www.homedepot.com/p/RIDGID-1-1-2-HP-Compact-Router-R24012/100337039

It's not too powerful but I found it very easy to handle.

  1. The stain application was trial and error on a couple of early boards. I had tried some of the techniques posted here, including very dark all over stains, paints, and burning and wire brush, but none of them really achieved the look I wanted. So i kind of made up my own method. Here's a couple more pics:

My first step was pencil drawings, and then routing with the straight edge bit to a depth of about 1/4". Then I sanded lightly with an orbital sander and lightly burned with a propane torch. This is the result:


Next, I took a small brush and laid dark outdoor stain into the groove - the "negative space" - to darken the actual image. It looks like this:

Then I added color stains to the rest of the images, usually a couple of coats as the translucent stain is very lightly colored. And a final coat of polyurethane on top:

All the stains were from Home Depot, Behr Semi-transparent, which I got in small sample sizes. They tint to your requirement:

http://www.homedepot.com/p/BEHR-Premium-1-gal-Cedar-Naturaltone-Semi-Transparent-Weatherproofing-Wood-Stain-553301/202263889?N=5yc1vZbbbmZ1z10m0l

As this is an outdoor bar, it's got several lays of poly on it. I started in most cases with Polyshade to give the non-stained wood edges a golden tone, then followed up with Helmsman outdoor poly.

http://www.homedepot.com/p/Minwax-1-qt-PolyShades-Pecan-Satin-Stain-and-Polyurethane-in-1-Step-61320444/202061444

http://www.homedepot.com/p/Minwax-Helmsman-1-gal-Satin-Spar-Urethane-13205/203003564

It took a long time, but it gives a rich layered look to the trim that doesn't really come over in the photos. the colors really pop in the sunlight.

Hope that helps!