Challenge: Restore existing surfaces and replicate new surfaces to match the remaining original finishes in the residence.

Our client had great vision and exacting standards for the replication of finishes in this residence. Of utmost importance was the belief that all completed work should look original to the residence. We encountered some challenging requirements with this project, and took great care in crafting the processes necessary to meet the expectations of our client.

The residence consisted of old growth Douglas Fir on every surface. This vertical grain (quarter-sawn) required the creation of unique processes in order to control the inherent blotchiness which is so common in soft woods of this nature.

The challenge for this room was to replicate the existing feel and depth of the original finish of an adjoining room. The most complicated factor of this project was the reclaimed beams. These beams were solid structures that spanned the entire room. The exacting finish for these beams was paramount to the success of all our finishes in this room.

The client gave us the requirement that the beams would not have a film forming final finish. That is, these beams had to have the look and feel of the original beams that already existed. Three challenges were evident right away. First, these beams had mineral streaks that were created by iron spikes driven into them that had leached chemicals into the wood for years. Second, the checking and splits that occur naturally had to be emphasized as occurring over a long time period. Third, the finish process had to be created to control color penetration while not adding a film forming final finish.

Challenge number one was a relatively easy fix. The removal of mineral streaks created by iron deposits required an acid wash solution to be applied over all beams in their entirety. This process removed the iron stains but also caused the Fir to take on a rose tone. This was a planned event that enhanced our final finish.

Challenge number two was to enhance these checks, splits, etc. in a way that would create an impression that these beams were original to the residence. If these beams were truly original, the color inside the checks, splits, etc. would be the aged raw appearance of the wood core. To create this effect, we mixed a liquid wax solution and then hand applied a number of these checks and splits with our product. This very important process created a way for these checks and splits to stay their original wood core color when the rest of the beam would be aged.

Challenge number three was by far the most difficult part of the equation. We had to create a process that allowed us to color and age the beams, control the color penetration, and leave a non-film forming final finish. We went through several theories on how to do what seemed impossible. Finally, we created a process that on paper seemed like the winner. First, we created a wash coat of our favorite product (shellac) and applied it in a way that did not create a full film finish. Then we applied our color coat, which consisted of a water based dye (created with dried walnut husks). Lastly, we applied an oil based dye. This dye was created by using an alcohol based dye and fooling it to bond with an oil glaze, through the use of a symbiotic additive. The creation of this product allowed us to deepen the color, add depth, and enhance the age of these beams. We also were able to complete the most challenging part of the equation. That is, to not have a film forming final finish.

The final result was nothing short of spectacular. The room looked like it was original to the house, and since the completion of the project both the clients and their guests have admired the beauty of the residence. We were grateful to be part of the process.