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How to Get a Perfect Varnish Job

Today was perhaps the greatest day in the entire boatbuilding process. After 5 coats of varnish, I had a lovely, dust filled, non-skid finish. Each coat had dust in it from one place or another. Every coat was sanded with 400 grit paper. After the last one, which was not too bad, I was tempted to leave it, in my rush to get the boat in the water. This afternoon however, I tried sanding a sample piece of wood that I had been varnishing for this very purpose. I sanded with 400, then 800, then 1000, then 1200, and then used rubbing compound to bring up a high gloss shine.

Here's how I do it in more detail:

After several coats of varnish, which should be wet sanded fairly smooth between coats with 400 grit paper, you can either leave it, or add in a few hours of work to get a not so perfect job, perfect. First up, wet sand with 400 or similar grit paper. All shiny spots(these are low spots) should be taken out while using 400 or 800. After this, the paper really doesn't take much varnish off so it will be hard to sand them out. You should sand in increments of 400 or less really. I went 400, 800, 1000 and finally, 1200. You want to end up somewhere near 1200. At this point, you will see that the deck is almost shiny. Overall it is dull, yes, but if you look at the right angle, you can see reflections. This picture shows the deck after being sanded with 1200 grit paper. (Click thumbnail to see full size image)

Here comes the fun part. Rubbing compound! I don't know what grits to use, but experiment on a scrap piece of wood. I found that the piece of deck that I cut out for the hatches was quite handy for this. But any similar wood will work. Slap a few coats of varnish on when you varnish your deck, but don't go crazy on quality. It is just a sample. I had old rubbing compound that a neighbor lent me in an unlabeled 1 gallon can, so I can give no advice on what kind to get, sorry. The key is just to experiment and see what works! You might need to use two or more grades of compound to achieve the desired result.

When using compound, the easiest way is to use an electric buffing wheel(shown in picture below). but be careful! You want to smear some compound on heavy, then hit it at low speed with a nice soft pad on there. Watch out because this stuff will splatter all over. Keep the pad moving around, don't stick in one spot or it will heat up and burn right through your varnish, leaving the forever-dull epoxy showing. If the compound is dry, you're done. Wipe it off with a soft cloth(need a little elbow grease). Just make sure to go easy and don't burn it. More pictures:

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