Tag Archives: plywood floor

The Saga Concludes {installing plywood flooring, part III}



By the end of the week, we were definitely ready to put a period on the flooring project.  We spent the week trying to walk on rugs and blankets to keep the floor clean and protected.  We’re adults, so it was aggravating but not horrific, but Waylon was confused and annoyed about the whole thing, especially since he basically had to stay in the laundry room or bedroom or outside.

For the final coat on the floor, we used an oil-based polyurethane.  We were hoping that it would hold up better, and it has overall held up well (we at ten months of use now), but the oil base meant that it did yellow the stain, and because we blasted this thing with four coats, the yellowing was fairly significant.  I think that I would use water-based if we did this project over, in hopes of retaining the original stain color.

2015-12-04-02The actual application was pretty easy.  We thoroughly swept and vacuumed the floor, and then began working our way around the house and out the back door.  We purchased an applicator that was basically a mop with a pad that could be attached, and we used that to spread the poly around.  The poly that we chose claimed that sanding between coats would not be necessary.

Our biggest mistake, I think, was that even though we allowed the required amount of time between coats, we really probably should have extended that time for each additional coat.  It took a couple of weeks for this stuff to cure out completely.  While we were able to walk on it and use it within a day of the final coat, we had to be very, very careful to not twist our feet as we walked, or it would immediately wrinkle up the top couple of coats of poly.  This was still happening to some extent over a week later.  It got to a point where I wondered if it would ever cure!


But the shine!  I love a glossy floor, and that is definitely what we have.  This floor is A+ easy to keep clean.  I sweep and mop it with no issues.  It is just as easy to maintain as laminate.  (And look!  You’re getting a preview of a future post about our new entertainment center!)

So yes, we applied a coat, then had to go hang out somewhere else because the smell was unbelievable.  By this time, it was the first weekend of December and quite cold, so we were leaving windows open and the furnace on – not terribly efficient.  We had to stay two nights with relatives, and applied our four coats Friday night, Saturday morning, Saturday evening, and Sunday morning.

On the whole, the plywood flooring has been a win.  Even though it didn’t end up being much more cost-effective than some of our other options, it definitely accomplished our goals of stiffening and leveling the floor.  Eventually, we may put down laminate, but it should be able to blast right over what we already have.

The poly has held up fairly well, once it cured.  Waylon’s exuberance has definitely done a number on it and the floor is full of scuffs and scratches, but despite all his wild scramblings as he chases after balls, he has never cut down through all the layers to the actual wood.  We were really concerned about the scratches at first, but honestly now it just makes the whole floor look warmer and more like an old wood floor.

If this is something you’re thinking about doing, I think that the biggest thing we would change about the process is that we would have probably ended up with a smoother overall project if we had put down the wood and then rented a floor sander and sanded everything that way, and then stained it when it was already down.  The dust would have been stupid, though, so maybe we did it the right way after all.

Overall, I love the floor, and it’s sooo much better than our gross subfloor!  It was a ton of work, but the effort paid off!

Next time – tile for the kitchen floor!


In It to Win It {installing plywood floors, part II}


So yes, the floor project was one of those that began to rapidly spiral out of control.  We put in quite a lot of man hours with the prep work of cutting, sanding, and staining.  In the end, though, we had a huge pile of stained boards all ready to go.


So here is a “before” picture.  (That’s a friend’s dog in the picture… nothing like dogsitting while you’re doing major renovations!)  Most of the house was, at this point, subfloor painted with grey floor paint.  The floor paint held up so-so.  At first, it was fairly easy to mop/clean, but the gloss wore off fairly quickly, and it just felt like the floor was dirty all the time, especially with Waylon tracking in and out everywhere.


The kitchen, dining room, and part of the entry way had this lovely, classic faux-brick linoleum.  I had to take up the linoleum in the kitchen where we put down tile (more on that shortly), but for the parts of the house where we were putting down the plywood, we just blasted right over it.


The house is long and skinny, so we wanted the boards to run the width, rather than the length, of the house.  Otherwise we were afraid we would end up with a bowling-alley feel!  In this picture, the weird crack on the right is actually one of those hinges that run throughout the house.  you can also see those weird white spots – those are where we stiffed the floor.

In our house, under the subfloor is this weird honeycomb-cardboard stuff, and under that is another sheet of plywood.  (From under the house, all you see is plywood.)  In some places, that honeycomb is starting to break down, and those are the spots where the floor was getting spongy.  We drilled small holes in the area, sprayed expanding foam down in them, and then (after it dried), trimmed off the excess. It actually worked brilliantly.

Anyway, the main point of this picture is actually the putting down of our very first board!  Genuine excitement.  Once Pop and Tom figured out a system, it went down decently fast, but still involved a lot of measuring, cutting, and shimming.  It was time-consuming.


While they did that, I worked on taking up the kitchen linoleum.  It was stuck.  I used a heat gun to soften the linoleum, and then peeled it up using the multitool.  Another project that was pretty slow going!


It was pretty exciting to see the floor starting to take shape, though.  At this point in the process, the floor isn’t very well protected, so we were walking on rugs and blankets to avoid tracking it up.  We also had a bit of a hullabaloo because we had somehow underestimated the amount of wood we would need, which meant some extra cutting, sanding, and staining in the middle of the process!


It took the whole weekend to get the floor down.  Basically, we both glued and nailed the floor down.  It’s pretty well stuck!

At this point in the process, we had another work week ahead, and now we had to be extra careful on the floor, especially with Waylon.  Next step – clear coat!

It’s Easy to Bite Off More Than You Can Chew {installing plywood flooring on our own}


So those of you who have been with  me since the beginning will remember that way, way back when this whole adventure started, we had FLEAS.  Not fleas, mind you, but FLEAS.  EVERYWHERE.  FLEAS.  It was a horrific experience and still gives me nightmares.  The actual point is, though, that at that time we were forced to pull up every scrap of carpet in this house.  That had always been the long-term plan, but we were initially planning to just live with the old carpet until we decided what to do with the floors later.  The FLEAS meant that we had to move flooring up the list.

We took up all the carpeting and painted the entire subfloor with white primer paint – just like we were already painting on the ceilings and walls.  The whole house was white for a bit.  Later, we put down carpet in the lower room and also in the bedroom.  However, on the whole, Tom and I both prefer hardwood floors (or wood laminate), so we decided to hold off on the rest of the house.

Throughout many of our projects, having just the subfloor was actually great.  It made it super easy to work on all kinds of painting projects, to drag furniture across the floor, and to housebreak Waylon without a lot of stress.  Along the way, I did paint it all again, this time with high-gloss deck paint, which helped make it easier to clean.  (Although I will say that that paint didn’t hold up super well.)

So all of this background brings us up to last fall, when we were once again talking about various options for flooring this place.  We had a lot of challenges.  The three biggest?

  • The floor is quite uneven
  • There are actual hinges in the floor because this house arrived folded up
  • The floor was rather spongy in spots

Because of these things, we didn’t feel like we could go with our top choice of throwing down laminate.


We started kicking around other possibilities, and somehow stumbled upon some YouTube videos of people installing floor made out of plywood, which they cut into planks, sanded, stained, and polyed.  And we began to think that maybe this could be a cost-effective way of doing what we wanted to do.

Menard’s periodically (but randomly) has 11% off rebate weeks, where you can get 11% back on all purchases.  One of those weeks came up in late October, and we decided that we would take the opportunity to go ahead and purchase all the plywood.  Then we could work on the project throughout the winter, taking our time to plank, sand, and stain.

The stack of plywood was rather staggering.  Just looking at the sheer amount of wood it was going to take made me worry that we were making a mistake – because it was going to be a lot of effort to get that wood smooth enough to use as a floor!

Now, Tom’s dad has been an invaluable aid to our whole life here, and we have depended on him heavily for advice, assistance, and insight, but every once in a while he turns into the catalyst that sets us off on a whole adventure that we were planning to do eventually but not right now.  Once Tom started cutting the plywood into planks… the whole project spiraled rapidly out of control, per usual.


Pretty much the first project was to build a nice sturdy table with one sheet of plywood for its top.  (We’ve actually kept that table in the barn and it’s fantastic.)

Next, Pop rounded up a long piece of straight metal from somewhere or other.  He and Tom clamped it down and used it as a guide to cut the plywood sheets into 8″ planks.  This meant we had one narrow board left from each sheet, but we worked those into spots against the wall.

It was AMAZING how fast the pile of planks grew!


Meanwhile, I was outside the barn doing my usual thing – sanding.  (Seriously, our little orbital sander is my best friend.)  As you can see, the planks were pretty rough.  Plus, plywood tends to have a LOT of writing on it.  It was a seriously challenging sanding project.


But, as you can see from the before and after pics, I was able (for the most part) to get them sanded down.

However, that process was super, super slow, and the pile of planks looked virtually endless.  This was the point in the process when we began to realize that this was a cheap way to do the floors… as long as you consider your own labor to be valueless!


Luckily, Pop stepped in to save the day as usual.  He spent almost two full days sanding on these planks!  Ridiculous.

Meantime, I was wrestling with a big decision – what color to stain the planks??  We tried several different options, and honestly never came up with one that made my heart sing.  In retrospect, the whole project would have probably made more sense if we had used a higher-grade plywood…except that would have made the whole thing more expensive and kind of defeated the purpose.  So who knows?  All I know is that the grey stain that I really, really liked did not look right with the wide grain of this plywood.  (We’ve used it other places and it looks fabulous on narrow grain so.)

In the end, we went with a very dark grey, almost black, stain called called cinder.


We spent the entire weekend before Thanksgiving staining planks in the upstairs of the barn.  It was one of those endless tasks where you just crank up the music and go on forever.  The planks had to be stained on the top, and then on all of the edges, because we knew that there would be small gaps between the boards at times.


As we finished staining them, we laid the boards out in the upstairs of the barn to dry.  The boards actually looked pretty good stained, although it took a lot more stain than we initially thought it would, and I had to make an emergency run to Menard’s!

By this time we were two weekends in, and were planning the big installation for Thanksgiving weekend… to be covered in the next post!