Level Sanding Epoxy Bowtie Inlays Flush

Bowtie inlays—also known as butterfly keys—are a beautiful way to reinforce cracks in wood slabs while adding a decorative touch. When using epoxy to secure them, the challenge is sanding the inlay flush without leaving a visible halo around the joint. This guide walks you through the process step by step.

Why Flush Sanding Matters

If the inlay sits proud of the surface, it feels rough and interrupts finishing. Sanding too aggressively, however, can dig a depression into the surrounding wood, creating an unsightly halo. Controlled sanding ensures the bowtie blends seamlessly with the slab while keeping the surface level.

Tools You’ll Need

• Random orbital sander or sanding block
• Clamping cauls to hold the inlay secure
• Epoxy fill kit for gaps or voids
• Wet/dry sandpaper (60–320 grit range)
• Tack cloth and vacuum

Best Grit Sequence

• 60–80 grit: For leveling raised epoxy and wood.
• 150–180 grit: Smooths out sanding marks.
• 220–320 grit: Prepares the surface for finishing.

Step-by-Step: Sanding Bowtie Inlays

1. Secure the board. Clamp your slab firmly to prevent vibration while sanding.
2. Level sanding. Start with coarse sheets like 60 grit (25-pack) to bring the epoxy bowtie flush with the surrounding surface.
3. Smooth the transition. Once the bowtie is nearly flush, switch to 150 grit (50-pack) to remove leveling scratches and blend edges.
4. Refine for finishing. Use 320 grit (100-pack) for a fine, even surface ready for oil or clear coat.
5. Clean thoroughly. Vacuum and wipe with a tack cloth before applying finish.

Special Cases

If the epoxy bowtie sits below the wood surface after curing, apply a thin flood coat of epoxy over the inlay, let it cure, then sand level. This prevents low spots and maintains a seamless appearance.

Pro Tips

• Always sand across the joint to avoid creating a halo pattern around the inlay.
• Keep your sander flat—angled pressure will dish the surrounding wood.
• Work slowly with frequent checks; stop sanding as soon as the inlay is flush.

Aftercare

• Finish compatibility: Epoxy accepts oil, varnish, and polyurethane finishes once sanded smooth.
• Odor-free cure: Ensure epoxy is fully cured before final sanding.
• Maintenance: Bowtie joints last for decades with proper sealing.

FAQs

• Can I plane epoxy bowties? Avoid planing cured epoxy—it chips blades. Sanding is safer and more controlled.
• What if the halo still appears? Apply a light water pop before final sanding to blend sanding patterns.
• Do I need to wet sand? Only for the finest grits (220–320) if you want an ultra-smooth, dust-free finish.

Watch & Learn

With careful grit progression and technique, you can level epoxy bowtie inlays without haloing, leaving your wood slab strong, stable, and beautiful.