Background

Updated 4 Jan 03

There is a huge quantity of information pertaining to wood finishing.  Finishing wood seems rather simple on the surface, but nothing could be farther from the truth.  Finishing a cabinet, or any piece of furniture requires technique and time.  The amount of time spent on the finishing process is directly proportional to the quality of finish obtained.  A good finish can be garnered with good technique, and good equipment.  Obtaining an excellent finish requires 2-3x more lacquer, and significantly more TIME.  I wish there was a way around this, but there simply is not.

My initial experience with spray equipment and lacquer was quite frustrating.  I truly thought that I could obtain a perfectly flat finish with my HVLP spray gun and the right balance of air, lacquer, distance, and rate.  I have endeavored considerably in this arena, and have realized that it is simply not possible.  I have also realized that nobody can accomplish this.  I am not alone.  A perfectly flat finish can only be obtained via rubbing.   Any good automotive finish and high-end furniture finish is rubbed.  I have also learned that my skills with the spray gun are darn good.  I can in-fact equal a very good factory furniture finish with my spray gun without rubbing.  Commercial furniture consumers are quite pleased with the quality of finish on most furniture.  This method of finish is also common on speakers costing up to $20k.  This is the standard finish applied to my speakers. 

Standard Lacquer Finish

- 4-5 coats of pre-catalyzed lacquer sanded periodically between coats

- Satin sheen

- Honey Amber tint added for a slightly warm appearance

This finish is fairly durable, quite clear and looks easily good enough for my wife's living room.  She is quite finiky about such things.  She actually prefers this finish over the rubbed lacquer because it shows less dust.  I agree that this finish is quite nice and will be acceptable in all but the most discriminating homes.

Rubbed Lacquer Finish

- 10-12 coats of high gloss lacquer sanded periodically between coats

- Rubbed to an ultra high flat gloss

- Honey Amber tint added for a slightly warm appearance

After spraying, the cabinet will thoroughly dry in about 10 days.  I then spend 5-8 hours rubbing the cabinet with sandpaper, 3M automotive film, and automotive compounds.  The time is shorter if I don't sand-through the finish, and longer if a re-coat is necessary.   This process involves considerable sweat and toil, but the results are striking. The finish obtained is a very transparent film equaling that of the most expensive furniture available.  The finish is extremely transparent, allowing a crystal clear view of the lumber.  A $3000 dining room table might have a finish of this quality.  Such a table is not found at common furniture stores.

Why?

I decided to offer this option because time in the workshop is becoming a serious concern.  As of today I have an entire year of cabinets to construct.  I love the work, but my goal is to meet the needs of customers in the very best fashion possible.  While I would love to apply 10-12 coats of lacquer to all of my cabinets and rub them, this is not smart business.  Smart business is meeting the needs of customers.  Some customers don't appreciate the ultra high flat gloss.  Also, as I consider my long term future in this hobby/business, I have evaluated a mass purchase of cabinets from a commercial cabinet maker.  This disclosure might not be necessary, but I don't find the need to conceal the truth regarding anything.

I learned that for ME to purchase 1801 cabinets with good finish and construction in quantity of 25 pair the delivered cost is $380-$400.  I must also add that the sprayed finish from some cabinet makers was very unacceptable.  Their finish quality was apparent and commensurate with a lesser bid.  When I asked cabinet makers about 10-12 coats of rubbed lacquer the pervasive response was a slight chuckle, and the remark, "oh, oh, that's going to be expensive!".   I received estimates from $700 to $1000 per pair of 1801 cabinets, but none of the cabinet makers provided a solid response.  It was quite apparent that none of them normally performed this work, and that it would also be very time consuming for them. 

Outsourcing cabinets will likely happen if I continue this hobby/business.  As I look to the very long-term future I realize that I will have to build many more cabinets.  This will necessitate purchasing a CNC router or outsourcing cabinets.  While I will always perform woodworking, I realize that my my time is most valuable on more technical aspects of speaker building.  Hence, the CNC router is not a smart purchase.  Outsourcing cabinets is the smartest option.  The finish on these cabinets will surely be a sprayed finish.  Offering a slightly cheaper sprayed finish sets the stage for a mass cabinet purchase.