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Refinishing a custom wooden companionway box requires a multi-day cycle of sanding, filling, and fairing with epoxy to achieve a smooth, paint-ready surface. The process begins with shaping the wood and rounding edges to eliminate sharp corners, followed by a deep cleaning to remove sanding dust.0:29 For structural filling of screw holes and gaps, a mixture of epoxy resin and wood flour provides a thick, stable filler. Subsequent layers use a specialized fairing compound, such as West System’s Microlight, applied in thin coats to minimize the labor-intensive sanding required between passes.17:24 The project involves approximately six to seven days of alternating between application and sanding to reach a high-quality finish.12:37 After final sanding and cleaning with acetone, the surface is ready for a base coat of paint, which serves as a guide to reveal remaining surface imperfections.19:52 Proper preparation and clean application significantly reduce the time spent sanding, though the process remains tedious.4:46

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