For a varnisher, a box like this, on a bench, is the holy grail. It doesn't get any better!
This 56 year old deck box on my boat, needed 'wooding'. But the top is in the roughest shape. It get's walked on, used as table when grilling, etc. Plus it's the worst angle - level - on a boat for UV damage. I probably could have repaired the joints on the corners, but it's demise has come due to the top piece, which is plywood. Unlike solid wood, plywood veneer is only so thick, and my sander found the bottom of the veneer. Oh well, new top. The dovetail box itself is in perfect condition.
After about 30 minutes, carefully with a heat gun and stiff putty knife, about 15 layers of varnish was gone. Sanding was with a 6" RO and 80 grit paper. Then a quick pass with 120 grit(I usually end with 80) to remove a few swirls.
Materials- Interlux filler stain.
Hardware spar varnish ($16 per quart).
4' foam rollers, 2-3" foam brushes, all cheapies from the hardware. Small roller pan(s)
Here was the process from there:
Interlux filler stain, thinned(as directed), and brushed on with a throw away foam brush. Wait 15 mins. and wipe with a cloth. Allow to dry a couple of days(it's off season, nothing but time).
1-One diluted(10-20%) coat of varnish applied. (No sanding before).
2-A second slightly diluted coat. (still no sanding)
3- First sanding with 240 grit on a flat rubber block. Block flat until surface all fogged(few minutes). A third coat of full strength varnish applied.
4- A quick rub with 3M finish pad to remove nubs(my shop is hardly dust free). Apply 4th coat of full strength varnish.
The results so far:
Looks pretty good for just 4 coats. That's the beauty I find, in rolling and tipping varnish; it's a time saver while giving better results. The magic is in that you can apply an even, full coat, which is hard to do with a brush alone.
If you leave a flat even coat, you don't need much - or any - sanding between coats (the 3M pad gives enough tooth for the next coat). This is ONLY if you avoid runs and sags, which I find rolling and tipping helps to eliminate.
I'll put a few more coats on so the new coating will last between annual maintenance coats. I don't always use the hardware spar varnish, but I use quite a bit. It's not as good as the higher priced marine varnishes, but it's not that lesser quality in some applications, to pay 3 times as much.
Here's a partial shot of the bleached out deck box last season, against newly restored coamings.