Sawdust Diaries: Filler “Fun”esse

Welcome back to another episode of Sawdust Diaries! Today our whimsical wanderings are going to take us to the enchantment of Fillerland… the land where mystery and intrigue abound… where one mistake can lead to treachery and anguish… Ok, not really, but hey, sometimes you need to jazz up your introductions! But not all the hyperbole is exaggerated. When it comes to what you choose to do with the cracks and knots (assuming you want a smooth surface) there are a few topics for your cranium to consider! Let’s explore…

 

OPTIONS OVERLOAD

 

When it comes to wood fillers, there are a lot of options to choose from. I definitely have not used all of them nor do I pretend to be an expert. However, my personal experience groups these into three main categories: Epoxy-based, “mud”-based, and putty. We’ll look closer at these three and specifically the brands I use.

TROWEL-ON “MUD”

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There’s most definitely a proper name for this category of wood filler but sometimes describing it like it really is paints the perfect picture! In this case, and the product I use, it looks like someone scrapped up some dirt, sifted it really well, and added water to it… hence why I am calling it “mud”! Probably a better description of the consistency is that of a mix between whipped mayonnaise and sheetrock spackling… mmm, yum, anyone hungry?? The product I am talking about is Woodwise Wood Patch. According to their website (www.woodwise.com/wood-patch-full-trowel-filler/) they currently have 16 colors to choose from but I have only ever used Ebony for my reclaimed projects. It provides the contrast I am looking for to accent the saw lines, knots and nail holes. But enough pontificating, what makes this product good and what makes it bad?

PROS:

-Accessibility and cost. A one gallon tub can readily be purchased online and requires only a sheetrock knife for application (and maybe a mixing tray for thinning, see below)

-It can be tinted. Woodwise sells a “base” that you can buy and make your own color but I’ve personally only ever used “pre-mixed” Ebony. That being said, I have experimented with adding some Black Transtint liquid dye and it does make it darker if you do not like the somewhat grey appearance that sometimes results after sealing/finishing.

-It can be thinned. Similar to sheetrock spackling, you can add a little bit of water to make this filler more workable into thin cracks and pin holes. (Pro tip: Thin small batches as you go and do not add back the thinned with the non-thinned)

-Applies easily to the workpiece and generally does not sag when applied to a vertical surface. You’ll have to experiment with one to see what you can get away with. I’ve found that a dime-sized area or less on a vertical surface is about as large of “defect” as you’re going to get away with. (Pro tip: If you have say a quarter sized hole or knot to fill, locally apply the filler being sure to keep the surrounding area bare wood. Once applied, adhere a piece of wide painters’ tape right over that spot and that will prevent it from sagging out. It will take longer to dry though…)

-Speaking of drying, Woodwise wood patch dries fairly quickly. That being said, I’ve always waited a day just to be sure. Jumping the gun here only leads to clogged up sandpaper and a smeared mess of a workpiece!

– Sanding is generally a breeze with any orbital/finish sander or even by hand. (See below for cons related to sanding…)

-No harmful vapors. Full disclaimer, this stuff does not smell like roses and spring blooms! I still try to use a respirator when applying it. The main reason being I just don’t want prolonged exposure to what I know probably has chemicals of who-knows-what origin! Consider yourself warned and own your own decision here…

CONS:

-Does sometimes crack and chip out, especially when sanding with orbital or vibrating finish sander. Just be prepared to have a little bit of patience (sometimes a lot-a-bit!) and plan on applying a few coats. Especially if you’ve chosen to thin it down. Adding water does increase the likelihood of the filler shrinking and cracking once dry!

-Super dusty when sanding. I hesitate to even list this one because we’re talking woodworking and obviously fine dust of any kind is bad news. Nevertheless, knowing it is not a “natural” product and the color I use happens to be dark in color, I feel the need to reiterate the fact that your lungs would probably look like a tar pit if you don’t take the obvious protections of a really good dust collection system or a respirator, ideally both!

-Does not provide a glued or chemical bond. This is strictly a filler. If you are looking for a “bonding filler” you’re in luck, that is what we’ll talk about next.

But first, a general conclusion about Woodwise Woodpatch. I do highly recommend this product with the one caveat being that it is the only brand I have tried in this family of fillers. If you are making a project that will experience low to medium “traffic” and where a perfect fill of all the cracks and voids is not needed, this method is going to serve you just dandy!

EPOXY

 

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Another great filler option is of course epoxy. Woodworking purists will often scoff at putting “plastic” on your workpiece but I’m personally more accepting of that transgression when I consider the benefits it has to offer. Here too there are handful of brands to choose from but I will speak directly to my experience using only West System Epoxy. If you are doing a large project or plan to do multiple projects, I would recommend getting the ~127 fluid ounce container of Resin and the 27.5 fluid ounce container of Hardener. With these you will then be able to purchase and use pump covers. Buying the pumps makes mixing the right ratios a breeze! Trust me, there are more important steps that’ll require your undivided attention, mixing should not be one of them! One note on hardeners. I err on the side of having a longer working time because if it gets away from you there is nothing you can do! Therefore, I always use the Slow Hardener. Onto the comparisons… pros first:

PROS:

-Epoxy is tintable. Powder or liquid dyes of every color (and sparkle!) are available, the sky is the limit here! I have only tinted Black using Transtint liquid dye…

-Provides a chemical bond. Strong joints in any woodworking project are always welcome and in my opinion this is one of the best attributes of this product.

-Does not crack or chip out (generally). Provided you’ve mixed everything well and the surface of the wood is clean, the chance of epoxy separating from wood is very low.

-Can be applied locally using a syringe. Being able to locally apply epoxy to where you need it greatly reduces the amount of sanding later. Two drawbacks here are that you can only mix small batches and it is more tedious to apply.

CONS:

-VERY toxic and noxious fumes! Wear a quality respirator and work in a large, well-ventilated area!

-Flows everywhere… Sealing for leaks should be your top priority during prep. First, vigorously clean the underside of whatever it is you are filling (i.e. a panel of barnwood). Second, apply wide painters’ tape or Tyvek tape to all the joints, firmly press it all down. Three, place a sheet of plastic under and around your work area as insurance. I have put this in the cons section to emphasis the point that you will have a disaster on your hands if you ignore this property of epoxy! Its’ flowability is an obvious benefit as well. More often than not that is the point in using it. To fill any and all cracks so you have the smoothest surface possible!

-Must be monitored during filling and after. Because of its’ ability to flow into all the small voids and crevasses, it will at times feel like you are endlessly chasing bottomless pits of despair! Here again, patience is the only prescription for avoiding a mid-project termination!

-Is also quite “dusty” when sanding. Same advice as before: Use a Quality respirator at the very least!

So, if you can work safely in a ventilated area, have the time to fully seal your project for leaks, and are able to monitor/babysit the application process to pop bubbles and chase those voids, epoxy comes highly recommended by yours truly!

Depending on how much lumber you must clean, this way will definitely test your grit and determination but keep at it and you’ll be rewarded! Secondly, sanding sponges of varying grits (60, 80, 120) will also be a nice addition to the hand cleaning approach. Having a chisel or two as well as a utility knife won’t hurt either as there are larger slivers and such that are better off completely removed to avoid them resurfacing later in the project.

PUTTY TO THE RESCUE!

 

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Finally, we’ll touch on an option that has the most merit in those instances where a small crack or defect needs a re-touch. If after sealing and finishing a project there magically appears a crack or pin hole, the product I lean on is made by Minwax. It is a non-hardening putty that can be smeared on by hand. Generally, it is used for filling nail holes in unpainted or stained trim. It comes in a variety of natural wood colors but again, the one I’ve primarily used on my reclaimed projects is Ebony. Just smear it on/in and wipe off excess, it’s that easy! I wouldn’t recommend using it on a whole project as your finger and thumb pads would be quite raw and blistered by the end! This is a non-bonding filler similar to Woodwise Woodpatch…

FILLER FINALE!

 

So, there you have it! Three options for filling cracks and defects in your reclaimed barnwood projects! As a final word of advice, whatever method you choose, start on a small project or sample and get to know the products’ behavior and nuances. Don’t tackle two seven-foot dining room table tops like I did at once only to double your time fixing issues! Admittedly, at times this subject has been a source of great frustration for me as I’ve found each method has its’ merits and pitfalls. Hopefully you have found this a thoughtful discussion and can take away something useful to use on your projects. By no means is this a complete write-up on the subject so pick up where this leaves off by launching into your own investigation and discovery! Somewhat selfishly my intent with anything here on this blog is to share what I know so it becomes more enjoyable! That’s right… as Bob Proctor once said, “You don’t really enjoy something unless you share it!” Seems counterintuitive to share something that is frustrating but the more I think about it and open myself up to experiencing the joy of sharing (even frustrations), the more it rings true. And on that note, if you have anything you’d like to share on this topic, please do leave it in the comments! Until next time, Happy Feelings… er, Filling(s) …whatever… you know what I mean… (wink!)

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