My new best friend:
Luckily, my dad has this handy little disc sander. It saves a ton of time on flat surfaces. It uses little sandpaper discs that attach to the sander with hook and loop:
Best investment ever.
I had to sand a lot of flat surfase stuff with 120 grit and then 220 grit before I could get to the staining phase. This is what it looked like at about 3PM yesterday when I was finishing up with the 120:
Out of the frame is the huge stack of uncut poplar that we're using to trim the thing with. We decided that we would sand and stain before we start o cut and trim. It will hopefully save some time in the long run.
Afterwe sanded the door frames with 120, we routed a pencil edge on the interior edge of the front of the doors and hand sanded a tiny curve on the outer edge:
And we had to route the back of the frame where we will place the face, which will be made of 1/4" birch veneer ply. It went smoothly:
Except for one door, which did not go as smoothly. It started to splinter as we routed the first door. We figured out that we needed to take off smaller amounts and take several passes before we got tothe final finished route. All wasle to use some wood glue to get the splinters back in place without breaking them off:
It sanded out just fine and you can't tell from the front of the door.
Unfortunately, the sander will not work all that well on millwork. All that stuff had to be done by hand. 120, then 220. It took forever:
Finally, at the end of the day today, I got the first piece of poplar stained with the first coat:
The method that I had to use on the poplar is one coat with no wipe. Let dry for 4 hours. Steel wool 00 over the whole thing, and then stain again with no wipe. I have to work VERY hard in order to get the stain even with no streaks since I am not wiping the excess off, which usually evens out your coat. It's an art!