by doug hodder » Sat Jun 01, 2013 9:39 pm
I've done 4 tears using just epoxy resin only, no cloth. If you want a woody, it's going to take a fair amount of prep work to get a good finish. Don't use an oil based stain. Get a water based aniline dye for best results. It takes several coats of epoxy to really build up a nice finish. I do a bunch (6), but want it to be as smooth as possible. The more you put on and sand...the smoother it will be. You can't put it over a hard 90 corner, it will tend to split and crack over time. All the edges need to be eased. It applies easiest with a roller, get the official epoxy rollers, the cheap ones from HD will break down in the resin.
If you are going to go that way, get some good wood for the outside. It's a lot of work and effort so make it pay off with some nice looking material.
If you want to paint it...put on the epoxy layers, sand down to give it a tooth and paint it.
Whether it's a woody or not, epoxy resin needs to be top coated to protect it from UV. I use automotive clear on a woody, or just paint on the painted ones. Marine varnish will work, but will require more maintenance. Boats typically get a new coat of varnish regularly to keep the nice bright look. Others opinions may vary, just what I've experienced. Doug