Layered epoxy inlay #3: First layer sanded

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Blog entry by JoeyG posted 01-06-2012 06:59 PM 6584 reads 0 times favorited 9 comments Add to Favorites Watch
« Part 2: first two colors in Part 3 of Layered epoxy inlay series Part 4: Layer two »

Here is what I woke up to. You can clearly see where I cooked it a little to much in the red. You can also see where I tried to pop a bubble on the green. Luckily it is over the wood that will become the horn.

I grab my trusty new bosch random orbital sander, which I love, throw on a slightly used piece of 80 grit. It was a piece I used for the sculpted box on my other blog, the edge was ate up but the flat of the disc hadn’t been touched. And I got nowhere. It seems I have about 1/8 of an inch of epoxy, maybe thicker in some places.

I sanded on it for about 5 mins and decided I was moving way to slow. So I went over to my planer and being very careful that I didn’t touch the tape or wood, gave it a couple of passes. I know this probably isn’t good for my blades, but it’s about time to replace them anyway. If you look carefully you can see flakes of epoxy laying on the face.

This left me maybe a 1/16 above the level of the wood. With the 80 grit on my orbital it only takes a few minutes to get it down level with the surrounding wood.

Here you can see it with the overlay on it. I still haven’t figured out how I am going to transfer it. I am about to head back out to the shop after lunch with my daughter and try to figure it out.

Here is the original drawing just as a so you can see them together

One last note:

This is where I would normally mix up more epoxy the same color and I started with and fill in any voids left by air bubbles. I am not doing it now for two reason, one is that there are not that many and second it that I will be routing out some of the epoxy for the rest of the details. Hopefully this won’t come back to bite me. We will find out.

The next episode will hopefully be today or tomorrow. If I decide to get carbon paper it may not be up till Monday, but never fear, it will be up soon.

Any questions or comments or ideas are welcome as always.

-- JoeyG ~~~

9 comments so far

View Karson's profile


35126 posts in 4429 days

#1 posted 01-06-2012 07:13 PM

Joey: That’s looking great.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware soon moving to Virginia †

View SPalm's profile


5320 posts in 3911 days

#2 posted 01-06-2012 07:54 PM

I would think that a router on some rails would level that pretty well too.

It will be interesting to see how it comes out.

-- -- I'm no rocket surgeon

View Eric_S's profile


1565 posts in 3224 days

#3 posted 01-06-2012 08:00 PM

Thats, going to look great when it is finished Joey. I’d go with steves suggestion of using a router on rails, your going to be destroying those blades on the planer. I posted a simple router planer recently on my projects, very easy to make and use.

-- - Eric Noblesville, IN

View JoeyG's profile


1275 posts in 2654 days

#4 posted 01-06-2012 08:43 PM

That’s a great idea with the router. I’ll have to make a jig for it. I need to replace my blades anyway so I wasn’t to worried about it. I’ll be replacing them soon, so a jig will probably come after I finish this one. Thanks for the idea, I would have never thought of it. It’s always the obvious ones we miss.

-- JoeyG ~~~

View jaykaypur's profile


4017 posts in 2437 days

#5 posted 01-07-2012 12:29 AM

Amazing work!

-- Use it up, Wear it out --------------- Make it do, Or do without!

View gfadvm's profile


14940 posts in 2719 days

#6 posted 01-07-2012 04:30 AM

Joey, That is coming along really well. I too have run some stuff through my planer it wasn’t intended for but I have found that it doesn’t hurt the blades nearly like I thought it would. Now dirt and the finish on prefinished wood flooring will kill blades FAST so I don’t do that anymore. Do you feel like the epoxy hurt your blades?

-- " I'll try to be nicer, if you'll try to be smarter" gfadvm

View JoeyG's profile


1275 posts in 2654 days

#7 posted 01-07-2012 05:39 AM

Hi gfadvm, glad to hear I am not the only one to abuse my equipment a little. I don’t think it did much to the blades. It may have dulled them a little, but that’s about it. I am more worried about milling up a batch of wenge than I am about that little bit of epoxy. I have used my chisels before and haven’t notice any damage or undue dulling of them. I don’t like to do that though. I gouged a piece pretty good when the epoxy chipped and try to stay away from the chisels.

I will agree with the old flooring. It is designed to be hard. I usually take a card scraper to something like that.

-- JoeyG ~~~

View gfadvm's profile


14940 posts in 2719 days

#8 posted 01-07-2012 06:27 AM

Joey, You gotta get a drum sander. I now have 2 (a 10” and an 18”). They are the answer for highly figured wood and other stuff you are worried about wrecking with the planer. I looked on CL for 2 years and never saw one, then a friend told me he had one he never used and I bought it for about 1/4 new price. Sell some of your creations and buy one with the proceeds. Mine takes that finish off flooring REALLY fast. Many guys on here have built their own but I’m not that talented. You probably are!

-- " I'll try to be nicer, if you'll try to be smarter" gfadvm

View JoeyG's profile


1275 posts in 2654 days

#9 posted 01-07-2012 04:27 PM

I would love a drum sander. I am not sure I have room for it. I will have to post pics of my shop soon. It’s a one car garage. Long and narrow. I may have to make space at some point in the future. As far as making one, I am not that mechanically inclined. I wouldn’t even know where to start. LOL

-- JoeyG ~~~

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