Hi,
I am looking to repair an old oak floor that is constructed of recycled oak cladding, the floor has several long splits and voids in the planks. Having searched on line one option I have found is to fill the voids/cracks with a clear resin mixed with either the wood dust produced when the floor is sanded or perhaps wood shavings produced when the floor is planed to remove raised edges. I can find no topics on the help site that provide guidance on a project like this and I have the following questions:
1. Is this a viable project for use of a clear resin?
2. If viable what resin should I use? Looking at the products available GlassCast 50 Clear Epoxy Casting Resin looks to be an option but would IP2 Polyester Infusion Resin also work as it looks to be about 50% of the price of the Epoxy Resin?
3. Will the resins set if sanding dust or wood shavings are added to try and make the resin look more like the original wood?
4. If adding sanding dust/shavings does not produce the required effect can the resin be stained?
5. Some of the voids to be filled are deep (25 mm) and some go through the plank and I am unable to lift the planks to access the underside. Is there anything recommended that can be pushed into the crack to form a base to pour the resin onto to prevent it going straight through the plank. The planks are stable so the resin is not required to add to the strength of the plank.
6. Depending on the resin finish achieved I may fill the gap to the level of the surrounding surface. I plan to finish the floor with either varnish or wax oil, will either or both of these work with the resin finish?
7.  Is there any other advice you have for a project like this.

Sorry for all the questions but I have no experience of working with resins.

Thanks

Mike Snowden

It would be a waste of a clear resin like GlassCast 50 but there aren't many other options.  The only cheaper option would be a water clear polyester - however we do not currently sell one.  They are generally cheap and good for projects like this.  You would have to accept the need to sand the surface once cured as it remains tacky when air cured.  Other than that it would be the cheap way of doing what you want. 

In terms of stopping resin leaking through, you would have to know where you are going to have this issue.  Massively increase the wood content of the mixture and as a gloopy mess it should block up the gaps anyway.  You can go back and touch up with more if it sinks a bit. The wood mixed resin would likely look darker than the standard wood finish.

Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant

Warren

Thank you for the very quick response and guidance, I will have a look around and see if there are any polyester resins available. Also thank you for the tip about making a thick resin mix so it does not flow through the cracks and the note on likely colour.

Mike