If this is your first visit, be sure to check out the FAQ by clicking the link above. Then she and her husband built their rustic creation using 2-inch thick pieces of white oak affixed to a plywood base. The trick is finding a durable (fairly hard) wood that will remain fairly stable and also match the design style of the room in question. Once the countertop is removed from the mold, there will be a subtle orange peel” texture to the concrete which is removed with the quick action of a wet-polisher and diamond polishing pads. Use this handy guide to concrete countertop supplies which includes a description of everything you need to build a concrete countertop including types of molds , and more.
However, it was basically a large hunk of raw wood sitting in the middle of our kitchen-an attractive hunk of wood, but not the most useable surface. Depending on the caulk you will need to wait 1hr-12hr’s for it to cure before you can pour your countertop. But of course just like any upgrade, our new desk is making the rest of the room look terrible. If you need to make a cut-out for the sink and range top, use the old laminate countertop as a guide.
When cutting the plywood, note that it should extend beyond the base cabinets by about 1 inch, ensuring that the front edge is substantial enough to support the edge tiles. I have a already installed wash basin,,,so it makes it a bit more challenging,but heading for a under washbasin drawer cabinet. Usually you make them out of wood planks (like we did in our other bathroom and for our farmhouse table ) but to do it right you need a joiner, table saw, planer (or belt sander), kreg jig and bar clamps. Again, use a putty knife and crowbar (if necessary) to pry the countertop from the cabinetry.
Start by measuring your cabinets that the counter will be sitting on and cut the plywood with a 3/4″ overhang on the front. If you have any experiences in working with teak or questions on how to design or build your own teak counter top feel free to leave a comment for us. In this video, This Old House general contractor Tom Silva shares his secrets for fabricating a stylish new plastic-laminate kitchen countertop. Bend the rebar into a frame lining the inside of the mold and then fill in the frame with a grid of wire mesh, creating something that looks like a cage. To everyone’s surprise-including mine-trimming the length of the countertop helped immensely.
Any type of basic tongue-and-groove flooring will work for this (our part of the country carries mainly fir – in other areas it’s pine), even used wood flooring, if you can find it for a decent price. One of the rules” of woodworking is that solid wood expands and contracts with changes in humidity. I love the section of butcher block I have in my apartment kitchen, and given that the rest of the room is mainly black and white, I worried that the concrete would end up making things feel too cold and flat——the kitchen really needs some wood color and texture to bring it to life and inject some warmth.
Specialized profiles and corner pieces produce stunning sink rails, elegant and easy-to-clean countertop backsplash transitions, and practical tiled-under sinks. It’s designed to demonstrate many of the most common details used by today’s concrete countertop fabricators. Check to see that the cabinet drawers will clear the front edge of your new laminate countertop.
If you wanted to know how to make space in your kitchen, the next section on how to build a pantry behind a door may be just what you’re looking for. That 60-grit sandpaper cut right through all of the rough areas and wood glue, and leveled out the boards quite nicely. Take care not to use the concrete for 2-3 friends, carefully flip the countertop over.
Tie off a sheet of off 5″x5″ welded wire mesh to the rebar frame and suspend 3/4″ from the top of your form. Carefully measure and mark the sheet of plastic laminate to the approximate size of the countertop; it should be large enough to overhang the counter 1/8 to 1/4 inch on all sides. The mold has to be watertight to keep the water in the cement from causing discolorations, blemishes and dry areas in the countertop.
Its a plywood carcas with shelves, clamp storage, and a place to store my lunchbox planer which I never use anymore. Originally I’d thought maybe I would put a thin layer of wood filler over the spackle, but it blended so nicely into the white wall that I decided it wasn’t necessary. Belt sanders take off a lot of wood FAST so you have to keep it moving and make sure you are sanding the whole surface evenly.
In order to reduce air pockets in the countertop and minimize cracking, the poured concrete needs to be vibrated in the mold, preferably with a professional-grade concrete vibrator. The first thing we did was cut out particle board (yes, you want to use particle board here because it is dimensionally more square than say plywood and less likely to warp – has nothing to do with the $17 a sheet price tag although that’s a bonus) about 2 inches bigger than we need.
Had to pay close attention to the edges, corners, where the wood was uneven and the rough spots…..this was the time to sand down any imperfections. Nice overall look, however, as a professional woodworker I would be concerned gluing solid 3/4″ thick Red Oak boards to plywood. For fine-tuning tile cuts, tile nippers are helpful-they break off small pieces for contours or complicated cuts.
Lastly, all of this, plus (not to speak for her), because she’s made this as a furniture piece” vanity, it can be floated in the room and there’s no need for it to be completely flush to the wall, because it’s not a fitted” piece. Then I flipped the boards over because I would be working on the bottom side of the countertop to put it together. I have seen one of them, and it has no gaps, the wood is like iron, and does not cut. And the chunky wood top is such a rich counterpart to the white cabinets, we really couldn’t be happier.
You don’t want a build-up stick on cabinet to contact the nose stick on the countertop, leave a small gap, it may prevent the countertop from fitting tight to wall. I got so excited about how pretty the countertop was looking that I started staining. Forming a concrete countertop with melamine, a type of wafer board with a smooth white surface, is the easiest and most economical way to build the mold. If you have a countertop edge trim, have your supplier cut it with a wet saw after all tiles are in place. Made of white melamine, it is simple to build and, above all, easy to maintain.
Using the original countertop sections as templates, trace their exact size and shape onto 3/4-inch thick medium density fiberboard (MDF). Remove excess cement from the completed counter with water or the cement solvent; use water or solvent sparingly so it doesn’t seep into the joints of the countertop. Different faces of the sawn wood will provide a different levels of durability to the surface.
Next, set your sink onto the plywood top and position it carefully with your tile layout in mind (remember, you’ll be adding 1/2 in. of cement board and tile to the front edge and a layer of tile on the backsplash). Be sure the pieces are fastened every 6 in. and that there aren’t any humps in the plywood. It’s OK to shoot from the hip like this with a rustic-looking countertop like ours.
It looks great in the room and has been a good surface for starting plants as well as holding goods for the freezer and baskets of laundry. We think it’s really important to get this right and create a clean edge with the silicone to avoid sanding and shaping cured concrete after removing the countertop from the mold. With several friends and colleagues working together, gently lower the countertop onto the cabinet tops. So you can simply push the countertop in place and secure it by driving screws up through the cabinet frame (special corner blocks are often provided for this).
If you are going to use a laminated material as a base for your countertop, you can prepare for tiling by working on the surface with sandpaper. Nora and I just switched on and off when our arms began to feel like Jell-, and it probably took about an hour (maybe more) for each countertop. I wanted to share with y’all, it gives us a ton of needed storage space and makes the laundry room look much nicer than it used to. I have six of his pieces, if you count the bar top, backsplash and cabinet panels as one.