by Ira » Thu Jun 15, 2006 7:58 am
Jason, I had the same problem, and I used 1/4".
All of my skins are just spar varnished, no stain, and as you can see from my avatar and other pictures, the varnish alone gives it a color and brings out the grain. (My side skins are birch too.)
Well, I made the mistake of installing the interior roof skin before varnishing, so I did the varnishing after it was installed. There's a certain trepdiation about finishing before you install it, because it will crack even when bending in the direction it's supposed to. And the FINISH could crack.
Anyway, varnishing on that rough side once it was installed, and trying to use the oribital sander between coats with that curve, I wasn't happy with the results at ALL and wound up covering it with tiki bamboo fencing. It was one of my many screw-ups, but it was a big one.
In your case, with paint, maybe you just want to sand that rough side down a bit. I think you would probably also be safe if you painted it on the sawhorses and then installed.
Here we go again!