Went through something similar recently with reclaimed barn wood flooring. Here's what I learned:
- Definitely underestimated the prep work. Removing old nails, sanding uneven surfaces, and dealing with warped boards took way more time than expected.
- Found that sorting materials carefully upfront saved headaches later. Tossing out questionable pieces early on prevented bigger issues down the line.
- Renting professional-grade tools (like a drum sander) made a huge difference. DIY-level equipment just wasn't cutting it for tougher reclaimed materials.
- Budget-wise, it wasn't cheaper than new flooring once labor and tool rentals were factored in. But honestly, the character and uniqueness of the finished floor made it worthwhile for me personally.
Would I do it again? Probably—but I'd be way more realistic about timelines and costs next time around. There's definitely value in reclaimed materials beyond just dollars saved, but it's not a shortcut by any means...
Your experience really resonates with me—I tackled a similar reclaimed wood project last year, but mine was a feature wall instead of flooring. Thought I'd save money by sourcing old barn siding, but between the hidden nails, splinters, and warped boards... yeah, it was quite the adventure. I totally agree about renting pro-level tools; my little orbital sander didn't stand a chance against decades-old wood.
One thing I noticed was how much extra material I ended up needing. I figured I'd have some waste, but it turned out way higher than expected because so many pieces were unusable or split during installation. Curious if anyone else ran into this—did you find your waste factor significantly higher with reclaimed materials compared to new?
Yeah, your experience sounds pretty familiar. I did a reclaimed wood ceiling in our dining room a couple years back and ran into the same issue with waste. Initially thought I'd have plenty of material, but once I started sorting through warped boards, splits, and hidden rot spots... well, let's just say my pile shrank fast. I ended up needing almost double what I'd originally estimated, which was a bit of a shock.
I do wonder if it's partly about expectations—maybe we're so used to the consistency of new lumber that we underestimate how much variability reclaimed materials bring? Or maybe it's just luck of the draw depending on where you source from. Either way, you're definitely not alone in this. Curious if anyone's found a good rule-of-thumb for estimating waste with reclaimed wood projects, because clearly my usual 10% buffer isn't cutting it anymore.
