Here I explain the stages step by step as to how the resin boards are produced, its a very similar process for the natural boards too.
Step by step
Choose the right piece of timber and cut down to roughly the right dimensions.
Once cut, plane the timber so that it is the right thickness and is a flat piece removing any cupping or bowing in the piece.
Using 40grit sandpaper all the planing marks are sanded out so I have a rough but flat piece.
Then I cut each side square.
After the first rough sanding I remove all the loose and dead wood using a wire brush in a power drill so that the resin has a stable surface to adhere to. Then the piece is thoroughly hoovered so that it is dust free of any debris.
Now I have to make a form for the piece to sit in to be ready for the resin to be poured. Each form is made to a slightly over sized size.
The form is then taped up so the resin doesn't stick and sealed to stop and leaks along the joins.
Place the piece into the form and choose the colour and opacity I want the resin to be. Then fill all of the voids with resin and top.
This is then left to set for a number of days until fully cured. Depending on the depth of the pour curing times vary greatly.
Once the resin has cure the form can be taken apart and then I plane the piece back again to remove the extra resin. I also run a saw along each edge to tidy them up.
Now that the final size of the piece is established I sand the piece again so that I can see any small holes that may not have been filled.
I can now fill these holes and leave to cure.
Once the final pouring of the resin is complete the sanding begins. Starting at 80 grit, I then sand with 100, 120, 150, 180, 240, 320 and finally 400grit so the board is super smooth.
Spraying with water in between to raise the grain of the timber so that it stays as smooth as possible for the customer.
Once all the sanding has been done I oil the board using a natural oil and wax mix and leave to soak in over night.this preserves the wood the best way possible.
The final stage is then 2 coats of natural wax to seal the wood and protects it the best and give it a beautiful shine