Figured I would share my experience replacing my wooden slats in case anyone else is thinking about doing it. I am by no means a pro. Made many mistakes and learned a lot through the process but happy with how it turned out. Hopefully people can learn through my mistakes at the very least.
For the wood I used Lowe’s “1x2x6 Select Pine”. I believe I bought around 6 boards but had some leftover. Price was fairly cheap. I like how they came pre sanded and smooth. I don’t have any sort of table saw, so I took it to a local woodshop in town and they cut it to the exact length for a total of $15. The wood is slightly thicker than original slats but you can’t really notice.
For the stain, I used Minwax oil based in Gunstock color. Now this is where I made a huge mistake. I was not aware that softwoods can have a blotchy finish when staining if you don’t use a pre conditioner. I applied 2-3 coats after the original coat thinking it would even out but it didn’t at all. I read online that a gel stain could help even out because it sits more on top of the wood.
I ended up using Minwax gel stain in Mohagonny as I wanted a darker color. I applied 2 coats. I would say it definitely helped but did not cure my blotchy issues 100%. Moral of the story…use a wood conditioner prior to stain if it’s softwood lol. I then put on 3 coats of Rustoleum marine spar varnish in high gloss. I did sand lightly between each coat as directed with 220 grit sandpaper. If you are going to sand, I would recommend getting a sanding block for a more even sand. I just used sand paper in my hand.
The finish is nice but I can still see some light scratches. I could probably put a 4th cot on top to fill them in but I probably won’t as it’s not that noticeable. The finish isn’t glass smooth either. Even though I sanded as directed, there appears to be some small bubbles in the finish. It doesn’t bother me, but for someone looking for a perfect professional finish you may need to use a different applicator. I used a natural bristle paint brush. Perhaps a foam applicator brush may have been better? I did stir the can as opposed to shaking it to help prevent bubbles as directed. I also have heard that Rustoleums marine spare varnish isn’t nearly as good as some other brands out there. When you compare prices, I’m sure there is truth to that as it is a lot cheaper.
Anyways, I am happy the way it turned out. My next step is to replace the lid handle with wood as well. Hope others can learn from some of my mistakes if they want to tackle this project. If anyone has tips for getting a smoother finish I would love to hear it. Thanks guys and happy grilling!
For the wood I used Lowe’s “1x2x6 Select Pine”. I believe I bought around 6 boards but had some leftover. Price was fairly cheap. I like how they came pre sanded and smooth. I don’t have any sort of table saw, so I took it to a local woodshop in town and they cut it to the exact length for a total of $15. The wood is slightly thicker than original slats but you can’t really notice.
For the stain, I used Minwax oil based in Gunstock color. Now this is where I made a huge mistake. I was not aware that softwoods can have a blotchy finish when staining if you don’t use a pre conditioner. I applied 2-3 coats after the original coat thinking it would even out but it didn’t at all. I read online that a gel stain could help even out because it sits more on top of the wood.
I ended up using Minwax gel stain in Mohagonny as I wanted a darker color. I applied 2 coats. I would say it definitely helped but did not cure my blotchy issues 100%. Moral of the story…use a wood conditioner prior to stain if it’s softwood lol. I then put on 3 coats of Rustoleum marine spar varnish in high gloss. I did sand lightly between each coat as directed with 220 grit sandpaper. If you are going to sand, I would recommend getting a sanding block for a more even sand. I just used sand paper in my hand.
The finish is nice but I can still see some light scratches. I could probably put a 4th cot on top to fill them in but I probably won’t as it’s not that noticeable. The finish isn’t glass smooth either. Even though I sanded as directed, there appears to be some small bubbles in the finish. It doesn’t bother me, but for someone looking for a perfect professional finish you may need to use a different applicator. I used a natural bristle paint brush. Perhaps a foam applicator brush may have been better? I did stir the can as opposed to shaking it to help prevent bubbles as directed. I also have heard that Rustoleums marine spare varnish isn’t nearly as good as some other brands out there. When you compare prices, I’m sure there is truth to that as it is a lot cheaper.
Anyways, I am happy the way it turned out. My next step is to replace the lid handle with wood as well. Hope others can learn from some of my mistakes if they want to tackle this project. If anyone has tips for getting a smoother finish I would love to hear it. Thanks guys and happy grilling!
