How to Sand Reclaimed Barn Wood to smooth after planing

Reclaimed Barn Wood sanding seems straightforward, but the final look depends on using the right grit steps and stopping at the correct finish level. Use the sequence below to smooth after planing while keeping scratch patterns predictable and easy to refine.

Why Sanding Matters

A steady grit progression removes the previous grit’s scratches instead of stacking deeper marks. It also helps finishes bond and look even—especially on edges, end grain, and high-touch surfaces.

Tools

• Sanding block (hard for flat areas, soft for curves)
• Vacuum or brush for dust control
• Clean microfiber cloths
• Painter’s tape for protecting edges/adjacent surfaces
• Bright raking light (flashlight held low to the surface)

Recommended Grit Sequence

• 80 grit – First cut / leveling step
• 120 grit – Remove the first grit’s scratches
• 150 grit – Refine the surface for finishing
• 180 grit – Final prep for a clean, uniform texture

Step-by-Step

1. Clean and inspect. Remove dust and residue so you can see scratches, shiny low spots, and edge damage clearly.
2. Start with your first grit and keep the surface flat. Use a sanding block on flats to avoid finger grooves. For this step, use 80 Grit (25 Pack) and sand until the surface looks consistent under raking light.
3. Remove dust and confirm you’re done with the current grit. If you can still see the original defect pattern (marks, burn shadow, fuzz, or shiny spots), stay on the same grit a little longer.
4. Move up one grit and erase the previous scratches. Use lighter pressure and longer, overlapping strokes. A good next step is 120 Grit (25 Pack). Don’t advance until the deeper lines are gone.
5. Finish with your final grit for this goal. Use 150 Grit (25 Pack) with light pressure. For the last passes, keep your stroke direction consistent so the surface reads as uniform.
6. Final cleanup. Vacuum thoroughly and wipe with a clean microfiber so dust doesn’t interfere with stain or clear coats.

Special Cases

Edges and corners: Ease edges lightly. Over-sanding edges is the most common cause of uneven stain or cut-through on coated surfaces.

Wide flats: Work in sections and overlap them so you don’t leave stripes. Use raking light to confirm uniformity.

Pro Tips

• Change sheets when they stop cutting. Dull paper burnishes instead of abrading cleanly.
• Use raking light every step. It reveals swirls and missed scratches immediately.
• Don’t skip grits. Skipping usually saves minutes now and costs time later.
• Widen your blend zone. The best repairs fade out gradually instead of ending abruptly.

Aftercare

• Let dust settle, then vacuum again before finishing.
• Before staining, keep the surface dry and dust-free for even absorption.
• Before clear coats, ensure the surface is clean so you don’t trap debris under the finish.
• Store unused sheets flat and dry to prevent curling.

FAQs

• Wet or dry sanding? For most raw wood prep, sand dry and control dust. Wet sanding is more common for sanding finishes at higher grits.
• What if I still see scratches at the end? Go back one grit, remove them fully, then re-finish with the final grit.
• How do I avoid swirl marks? Use a block, keep strokes consistent, and don’t move up until the previous grit’s scratches are gone.
• What grit should I stop at? Use the recommended sequence for your goal—your final grit sets the surface texture for the finish.

Watch & Learn

To repeat the same process you just watched without guessing, keep a small set of grits on hand and move up step-by-step. For this job, the most useful picks are: 80 Grit (25 Pack), 120 Grit (25 Pack), 150 Grit (25 Pack).

Once the surface looks uniform under good light, you’re ready to finish with more predictable results. A consistent grit sequence is the simplest way to make the end result look clean and intentional.