How to Choose the Best Exterior Stain Applicator

Paint brushes are used to apply paint or stain to a smaller surface area or in oddly shaped spaces. Bristles usually come in two types: natural and synthetic. Finding the best brush to apply stain will depend on the type of exterior stain you use.

Brushes are typically a budget friendly option. Even the highest quality brushes are less costly than paint sprayers. However, brushing on stain takes a lot more time than using a paint sprayer.

Natural bristles provide the best results with alkyd or oil stains. They are less likely than synthetic bristles to create brush marks. When back-brushing, the hollow filament of the natural bristle brush picks up excess stain and redeposits it in areas which will absorb more stain. Natural bristle brushes can be cleaned and reused for multiple projects, making them one of the best brushes to apply stain.

Synthetic bristles are best with 100 percent acrylic and acrylic or oil stains. Unlike natural bristles, they won’t become limp. Synthetic brushes are more budget-friendly than brushes with natural bristles. They can be tough to clean. Consider simply disposing of them when the project is complete.

Tip: A high-quality brush of any material lasts longer and may be worth the investment.

When applying an exterior stain, the shape of the bristles can drastically affect the finish of the stain. Most brushes have bristles that are square cut. Square-cut brushes are versatile but offer limited control. Brushes cut at an angle are called sash brushes. Sash brushes offer greater control for corners and narrow spaces.

Always choose a brush that is at least slightly narrower than the surface you are coating. 1- to 2-inch brushes are ideal for narrow surfaces like trim. A 2 1/2- to 3-inch brush works best for narrow boards, railings and cutting-in. For large surfaces, a 3 1/2-inch or larger brush is a good choice.

Applying stain with a roller can help cover more area in less time. When using this application method, roller covers slide onto a roller head, which then can be attached onto a pole. Similar to brushes, finding the best rollers for stain will depend on the type of stain you are applying. Natural fiber rollers are best with alkyd stains. However, they mat if used with acrylic or acrylic/oil coatings. Synthetic fibers should be used with 100 percent acrylic and acrylic/oil stains.

Roller covers come in a variety of naps. A nap is the thickness or configuration of a roller.
Naps come in different lengths. A 3/16- to 1/4-inch roller cover will give smooth results on smooth surfaces. A 3/8- to 1/2-inch roller cover is best for lightly textured surfaces. When applying stain with a roller on rough surfaces, like weathered exterior wood, use 3/4-inch or thicker roller covers.

Tip: A paint or stain’s manufacturer will suggest the best nap for various surfaces. Be sure to read the instructions on the container.

Spraying stain is an excellent way to get a uniform look over a large or complex surface. You can invest in an airless paint sprayer or opt for a budget-friendly pump sprayer. When you use a paint spray to apply stain, you can cover the surface of your project much faster than if you used a brush. Some stain may be wasted during the application process, however.

Airless sprayers are professional sprayers. They work well for high viscosity or thick products. The cleanup of an airless sprayer can be involved and take time. Follow the manufacturer’s instructions to keep the machine performing well.

Pump or pneumatic paint sprayers work well with less viscous or thinner stains. They can be cleaned after use and are usually compatible with a variety of stains. Check the stain manufacturer’s packaging on whether a pump sprayer is the right choice.

When you apply stain with a sprayer, you’ll need to use a smaller tip than you would with paint. Spraying stain also doesn’t require as much pressure as paint does. Check the tip size and the pressure of the sprayer as you are selecting the best exterior stain applicator for your project.

Here are a few tips to keep in mind when you're searching for the best way to apply stain:

• Work with the grain not against it.
• Don’t apply exterior stain in high heat or humidity.
• Even out any drips or puddles before they dry.
• For more professional-looking results, use a sprayer or roller to apply the stain first. Follow with back-brushing to eliminate drips and runs.
• Stain pads do an excellent job of applying the correct amount of stain, especially on smooth wood. You can purchase the head, which will attach onto a pole, along with several refill pads for your project. Pads are disposed of when the job is done.
• Using rags to apply stain is another option. Rags are not the best choice quick applications, however.
• When working with stain or paint, always make safety a top priority. Use protective equipment such as respirator masks, safety glasses and gloves.