How to Mix Shellac Flakes: A Basic Guide for Woodworkers

Shellac is a classic wood finish that has stood the test of time. It offers a warm, natural appearance, dries quickly, and is easy to repair. One of the key advantages of using shellac is the ability to mix it fresh from flakes, giving you full control over its strength and performance.

If you’re new to using shellac, this guide will walk you through the basic process of mixing shellac flakes for woodworking using metric measurements.

Why Mix Your Own Shellac?

Pre-mixed shellac is available, but it has a limited shelf life and often contains additives. Mixing your own provides several benefits:

• Freshness: Shellac begins to degrade after it’s mixed with alcohol. Mixing on demand ensures peak performance.

• Customisation: You can adjust the strength (called the “cut”) depending on the application—whether sealing, priming, or finishing.

• Long shelf life for flakes: Properly stored shellac flakes can last for years.

What You’ll Need

• Shellac flakes (available in various grades and colours)

• Denatured alcohol (ethanol of 94–99% purity, often labelled as industrial alcohol or methylated spirits)

• A glass or HDPE plastic container with a tight-fitting lid

• A digital scale (accurate to at least 1 gram)

• A measuring jug or beaker

• A stirring stick or clean shaker bottle

• A fine strainer or cheesecloth (optional)

Understanding “Cut” Strength

Shellac strength is referred to as a “cut,” indicating the number of grams of flakes per litre of alcohol.

Common cut ratios:

You don’t need to make a full litre. You can scale down as needed:

For example, to make 250 ml of a 200 g/L cut:

• 0.25 litres × 200 g = 50 grams of flakes

• Mix 50 g of flakes with 250 ml of alcohol

Step-by-Step Mixing Instructions

1. Measure the Shellac Flakes and Alcohol
   • Weigh the appropriate amount of shellac flakes using a digital scale.

   • Measure the correct volume of alcohol using a measuring jug.

2. Combine in a Container
   • Add the flakes to your container first, then pour in the alcohol.

   • Stir or shake gently to begin the dissolving process.

3. Let it Dissolve
   • Allow the mixture to sit for 6 to 24 hours at room temperature.

   • Shake or stir occasionally to help break up clumps and speed up dissolving.

4. Strain the Mixture (Optional)
   • Use a fine mesh strainer, coffee filter, or cheesecloth to remove debris or undissolved flakes before use.

Storage and Shelf Life

• Label the container with the cut strength and the date it was mixed.

• Store in a cool, dark place.

• Use within 3 to 6 months for best results. If it takes longer than 15 minutes to dry on a test surface, it has likely degraded.

• Mix in small batches to avoid waste.

Adjusting the Cut

If your shellac mixture is too thick for your application, add more alcohol. If too thin, allow it to evaporate slightly or add more flakes and let it dissolve. Different projects may require different viscosities, and experimentation is part of the learning process.

Mixing your own shellac is a simple and cost-effective way to enhance your woodworking finishes. It gives you full control over the quality and consistency of your finish and connects you with traditional methods that have been used for centuries. With just a few tools and a bit of patience, you can produce a versatile, beautiful finish suitable for everything from sealing bare wood to building up a rich, protective topcoat.

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