Extreme Refinishing




Introduction: I moved into my 1955 vintage ranch house in September 1998. The whole house has pegged oak hardwood floors except in the kitchen and bathrooms. One of the first things I did was to remove the nasty carpeting in the two smaller bedrooms. The hardwood floors in the 3 bedrooms were desperate to be refinished, but there seemed no good refinishing options. Basement water problems had caused the hardwood to become warped and cupped. There were several large dark stains in the master bedroom. A previous owner and gone through and nailed finishing nails between the boards in 12-16” rows. These nails were continually working themselves out and a source of annoyance when stepped on with bare feet. Add to this that the hardwood floors squeaked excessively and I came to the conclusion that only 1 solution was acceptable… extreme refinishing.

The plan was to carefully pull up all of the hardwood flooring in the bedrooms and hallway, run it all through my new Dewalt planer and put it back down. It sure sounded simple at the beginning. I pulled up the first 6 rows in the front bedroom and decided that the plan was doable. The sub-floor under the hardwood is ¾” diagonally run pine planks. I also decided up front that all of the baseboard molding would be replaced with oak molding after the floor was put back down. As things progressed I also decided that all of the bedroom & closet doors would also have to go. When I pulled the carpeting in the hallway, I was dismayed to find that it had been top-nailed with spiral nails, presumably by previous carpeting guys. After carefully pulling back some carpeting it turns out that the living room and dining room are also top-nailed. I'll have to find a new plan for phase 2.

Since I was getting married in October 2000 and as long as the hardwood was going to be up I decided it was a good time to demolish the existing closet in the master bedroom and frame in a walk-in closet.

    The order of events is:

  1. Put hash marks on the walls between the board where the baseboards used to be. Number them from row 1 to row X.
  2. Carefully remove and label each board so that it can be put back in its place.
  3. Remove all nails/staples from the boards (they're tough on the planer)
  4. Use 2 ½ “ screws to re-secure the plank sub-floor to the joists to help eliminate squeaks.
  5. Put down 15 # felt paper – overlapping at least 6”.
  6. Install new ½” plywood sub-floor over existing plank sub-floor and secure to joists with 3” screws. This will give the floor more stability and a better nailing surface for the hardwood.
  7. Do new closet stuff.
  8. Paint all rooms previous to re-laying the hardwood.
  9. Re-install hardwood.
HWF_01.jpg - 20417 Bytes Front bedroom

This is where I started. The boards had nastiness on the edges that would need to be removed later.
HWF_02.jpg - 18718 Bytes Front Bedroom Sub-floor and Closet

After pulling the floor up to this point, it was decided that the hallway would have to come up before any more rows in the front bedroom could be removed. Note the beautiful original pink color along the baseboards and doors.
HWF_03.jpg - 28283 Bytes Hallway – Looking into front bedroom

After pulling up the carpeting in the hallway, it became apparent that somebody forgot to use a drop cloth when they painted the hallway.

Note the original green color around the doors and baseboard.
HWF_04.jpg - 35411 Bytes Hallway - Detail

The paint is easier to see, but more importantly are the rows of top-nailed spiral nails. They didn't want to come up for anything. The double nailed 3 ¼” boards were the worst. It took me a week to pull up the hallway and I split or otherwise damaged a lot of boards. I didn't spend that much time on any other room.
HWF_05.jpg - 42664 Bytes The back bedroom

The back bedroom wasn't to bad, though it seemed to have more finishing nails than the other rooms.

Tools of preference include pry-bar, hammer and diagonal pliers for those pesky finishing nails.

Note the original in your face yellow along the baseboards.
HWF_06.jpg - 21197 Bytes The Front Bedroom – Preparing Sub-floor for plywood overlay.

After replacing a badly damaged plank, I ran chalk lines along the joists and screwed 3 – 2 ½” screws into each board along the line. With the sub-floor securely fastened it was time to lay down 15 # felt paper and ½” plywood sheets.
HWF_07.jpg - 21349 Bytes Front Bedroom – Felt Paper and Plywood sub-floor overlay.

Note to self: Be sure to mark location of floor vents on paper BEFORE securing plywood to joists.
HWF_08.jpg - 13279 Bytes Front Bedroom – Felt Paper and Plywood sub-floor overlay.

A different angle.
HWF_09.jpg - 48679 Bytes The Master bedroom closet and bookcase

The existing bookcase was handy and kind of cool, but the wood was putrid and the closet was just to small to accommodate two people. I used masking tape to layout proposed walls. I liked the “flow” the corner door would create, but later decided that I would only gain one useful wall and not be able to put any furniture where the dresser is shown.

Note the dark stained area on the left side of proposed door.
HWF_10.jpg - 15393 Bytes Out with the Old

Just like the other bedrooms, the floorboards were carefully removed.
HWF_11.jpg - 18696 Bytes Then the closet walls were less carefully removed.

Damn… looks like I'll have to do something with that conduit if I want to have a closet light.
HWF_12.jpg - 20176 Bytes Put down the new sub-floor

Once the new sub-floor was in, it was time to frame in the new walk-in closet.
HWF_13.jpg - 15584 Bytes In with the New

The closet went up surpassingly fast. New drywall all the way around, inside and out. Thanks to Arnie for letting me use his cool drywall sanding tool. The biggest problem was that the ceiling wasn't exactly level or flat. Note the dip in the ceiling where the arrow is and the bookcase was. All bedroom walls and ceilings were painted after the closet was ready.
HWF_14.jpg - 33081 Bytes Time to clean and plane

The boards on this side of the wood rack have been cleaned and are awaiting planing. The boards on the other side still need to be scraped. Let’s not even talk about the big pile of boards still up in the living room! Scraping the boards was a most heinous job. The edges of the boards had 50 years of debris and gunk stuck to them. I'm sure as the boards contracted and expanded with weather, "stuff" fell between the cracks and got stuck. Boards were scraped with a combination of the drill press with a nylon wheel and hand scraping with a putty knife. This was by far the worst part of the whole project. I dreaded coming home from work knowing that I had to scrape. Fortunately my wife Eliza (fiance at the time) helped me scrape on numerous occasions.
HWF_15.jpg - 28164 Bytes The Mighty DeWalt

What can I say… I love this planer! What a beast! Luckily I only hit 1 embedded metal object after I changed the blades. The only real problem I had was my poor electrical distribution. CB resets were common
HWF_16.jpg - 24630 Bytes Long Boards

A good number of boards were quite long. They were much harder to scrape.

Does the basement floor look like it’s ever seen water?
HWF_17.jpg - 23919 Bytes Putting it all together

My brother Michael was gracious enough to help me put this puzzle together. Good thing all the boards were labeled and color coded. It really only took a day to get the boards laid out. It took a week to swap out boards I didn't like or needed to fabricate using extra boards from the old MBR closet area.
HWF_18.jpg - 19479 Bytes Pre-assembled and ready for nailing.

The front bedroom with boards all laid out and ready for the pneumatic nailer.
HWF_19.jpg - 27046 Bytes The closet strikes again…

I knew I'd have work to do in the closet area. I did a lot of board swapping in this area to maximize the long boards in these rows. I plan to tile the closet and decided not to cut the boards at the closet door until I was ready to nail that row. I wanted a nice tight fit to the transitional threshold at the doorway.

After I had the closet framed and drywall up, Eliza came over (having not seen it yet) and causally remarked, "Why didn't you put the light switch on the inside of the closet?". D'OH! Ok, I guess I probably should have done that, but it didn't occur to me at the time.
HWF_20.jpg - 24784 Bytes Nearly assembled

For not being nailed, the floor looks pretty good looking across the room. The closet walls are actually finished in these photos.

Now where’s that pneumatic power nailer?…
HWF_21.jpg - 15826 Bytes Busy Work

It took the entire weekend to get the boards nailed in place using a pneumatic nailer. After getting all of the boards nailed I went through and filled all of the nail holes (from the finishing nails) with ZAR, oak colored, wood filler. I had purchased a gallon of filler and probably only used a ¼ of it.
HWF_22.jpg - 30279 Bytes Sanding Woes

It took me 2 weeks to get the floor sanded. I started out with the pictured pad sander and after an entire weekend of sanding decided that it wasn't cutting enough. The following weekend I rented a drum sander and edger combo and went to town. Ahhh.. much better. The drum sander didn't kick up much dust and was easier to use. Opps.. be careful how you set the drum down. The edger was much harder to use and left plenty of swirl marks.
HWF_23.jpg - 14498 Bytes All the hard work is starting to pay off.

Be careful not to apply stain wider than you can wipe it off (pictured above). Also don't forget to shut off lights behind you. The closet light in this room stayed on all night because I couldn't get to it by the time I remembered.
HWF_24.jpg - 23925 Bytes The Power of Lambs wool

I stained all of the edges with a brush and used a lambs wool applicator on a stick and MinWax golden oak stain out of a paint pan. The stick applicator worked very well and covers a lot of ground very quickly.
HWF_25.jpg - 24854 Bytes Half-Stained

Staining really makes a big difference and brings out the beautiful grain in this 50 year old oak. Almost done staining! YEA!

The polyurethane was applied in the same manner, except that I used a watering can filled with polyurethane and poured it directly on the floor. It took exactly 1 gallon for each coat of polyurethane.
HWF_26.jpg - 29651 Bytes The Hallway

The hallway after staining. After the struggle I had getting the boards up in the hallway and all of the holes that needed to be filled, I was concerned with how the hallway would turn out. It came out great!

Time for some polyurethane.
HWF_27.jpg - 13902 Bytes McCloskey Shine

3 coats of McCloskey water based, gloss polyurethane and the floors look sweet!

This is the master bedroom. The walk-in closet can been seen at right. The black strip is the felt paper moisture barrier that is underneath the hardwood. I decided not put a door on the closet since it would only obstruct access and because the dog sleeps in the closet. Since the closet will be open, I will put ceramic tile in the closet.
HWF_28.jpg - 32247 Bytes McCloskey Shine

The front bedroom is looking sweet as well. Guess I'm going to have to get those baseboard covers painted and put back on sometime…
HWF_29.jpg - 13875 Bytes The front bedroom closet.

A trip to Lowes and nearly $300 later, all of the closets have wire shelving. It took a closet to figure out how to put them up well, but after that it was easy sailing. I recommend starting with a closet “kit” (pictured above) before doing the custom closet with no directions.
HWF_30.jpg - 19148 Bytes The master bedroom closet.

A 4 foot level comes in handy – good thing my brother had one I could borrow… You know.. I really should have my own…

As discussed above, the walk-in closet floor will be brown 13” tiles.

I opted for a four foot, 4-bulb florescent light with oak crown moulding surround. You can never have to much light in a closet!
HWF_31.jpg - 32105 Bytes The master bedroom closet with tile.



This is the tile that I chose to put in the closet. It wasn't to hard a job, but the cramped quarters made it somewhat difficult to move around. It turned out really nice though and I'm very pleased with it.
Well, I'm late getting this picture up, but the trim has been up for six-eight months now and this project is done. We really like this large closet and the fact that it is open with no door to obscure any part of it.


I'm glad this project is finally coming to an end. It’s taken way more time and money than I originally thought. Still… it looks really good and now that it’s almost behind me, I'm glad I did it.

Update: Oct 2001 - It's been a year now and though the closet was tiled last fall, I still don't have doors or trim. There were budgetary constraints due to some apartments I shouldn't have purchased. They are all gone now and I'll soon be able to start thinking about purchasing doors and trim shortly!

Update: Apr 2002 - Most of my doors and trim are up now. The only interior door that is not installed is the bathroom door that won't go in until the bathroom project is done. A few updated pictures to follow soon.


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Copyright © 2001-2003 Aaron Montgomery