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Old 05-08-2009, 09:31 PM   #121
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my kitchen reno - complete remodel (with concrete countertop)


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We are gonna be doing concrete countertops also and want you to do all the trial and error work for me!
you have no idea how many people have said the same thing!

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I think a sawz-all without a blade would provide quite a bit of vibration, or a sander without paper
yes, you are right.. but i need to stick it into the concrete and move it around.. but to be fair, only the pro does that (or uses a vibration table), everyone else on the net who has made concrete countertop just shakes the surface walls or taps it with a hammer. nobody seems too concerned about this step. but i want to match what the pros do as close as possible.

i was thinking of a piece of dowel inserted into a wood block. and that wood block straped to the underside of my hand-held orbital sander. i will just make this device and see how it does. maybe try to mix some mud with it outside, see if it holds up.

my pour table is constructed, and i have my template in progress. i'm taking pictures and will write extensively on the subject when i finish each major step.

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Old 05-09-2009, 06:07 AM   #122
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my kitchen reno - complete remodel (with concrete countertop)


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and will write extensively on the subject when i finish each major step.

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ty
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Old 05-09-2009, 11:36 PM   #123
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my kitchen reno - complete remodel (with concrete countertop)


painted the kitchen today. 2 coats of Behr premium high hide primer (needed it!) and 2 coats of paint colour of choice.

but i gotta tell you about this paint. it comes in the funniest can, with a handle! this paint is ECO friendly, it went on really smooth with no splatters, dripping brush or shrapnel from a high speed roller. the colour is really deep.

NO I AM NOT A PAINT REP.. i just was impressed. in fact, i was so impressed i thought it deserved a moment of glory:



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Old 05-09-2009, 11:41 PM   #124
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my kitchen reno - complete remodel (with concrete countertop)


made the concrete countertop template today. was pretty straight forward. the recommended material was Luam wood, or "doorskin". i couldn't find it, so i used hard-board. basically any flat 1/8" thick sturdy material will do. just be mindful that glue must stick to it well (hard-board doesn't stick that great).

tools used:
hot glue gun
glue sticks
chop saw
marker
adjustable square

the 3.5" wide strips are pre-cut by HD. i just cut them to length as required. each piece is cut short by 1/2" so that i don't have to cut it twice.




Last edited by Knucklez; 05-09-2009 at 11:50 PM.
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Old 05-09-2009, 11:44 PM   #125
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my kitchen reno - complete remodel (with concrete countertop)


dry fit first.. here is my procedure:

1) i placed all the horizontal pieces first so that they laid flat to the substrate (plywood top on cabinet).

2)then i put the vertical bracing.

3)then i put the angle pieces.

4)then shifted stuff around to get the overhang i wanted.

when happy, i lifted the corners and started gluing with hot glue gun i got from the $ store today.
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Old 05-09-2009, 11:48 PM   #126
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my kitchen reno - complete remodel (with concrete countertop)


details of setting the template overhang:

i chose 1" because it seemed like a nice number and because it allows my farmer sink to sit just in front of it which i think will look nice.

i used my adjustable square to rest on the corner and to identify how far away from the substrate the overhang should be. since the metal ruler of my square is 1" wide this was easy. i just slide the template over the edge of the substrate until the template piece is flush with the square metal ruler part.



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Old 05-09-2009, 11:54 PM   #127
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my kitchen reno - complete remodel (with concrete countertop)


marking the template:

in the instructional video, the pro marks all sorts of information on his template. all i need to know is where the faucets are to be located. i basically stopped marking up my template after that because it seems like a waste of time. maybe he just does it so he has an official record of how that countertop was made so the pro can refresh his/her memory if customer calls 5 years later.? dunno..

anyway, i just put in where to find the faucet. the sink itself is easy to locate since it is a farmer sink, therefore didn't need to be marked on the template. hope i'm not wrong about that



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Old 05-10-2009, 02:18 PM   #128
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my kitchen reno - complete remodel (with concrete countertop)


Hi Knucklez: Glad to see everything is coming along. The Luam you refer to is actually commonly known as Philippine mahogany, or Luan with an "N". You are right it is used for doorskins, and should have been easy to find. But what you have is at least as good, if not better. The luan plywood tends to be very splintery when you cut it.
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Old 05-10-2009, 03:50 PM   #129
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are you going to use melamine for the mold? I know of a guy that was using a laminated mdf core sheet material that was ultra glossy, so when he pulled the top out of the mold he didn't have to polish or anything, granted that was the look he was going for without any aggregate showing etc.
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Old 05-11-2009, 08:46 PM   #130
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i'm just following the instructions given in the book/dvd published by taunton. they say use melimine, so that's what i'm going to use. keep the experimenting for method improvements to my next concrete countertop.

ps. we cooked our first meal in the new kitchen last night. it was frozen lasagnia from grocery store.. but it sure tasted like heaven.

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Old 05-11-2009, 11:21 PM   #131
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Knucklez, I haven't looked far back in the thread, but have you seen the book(s) by Fu Tung Cheng on the subject?
And one little idea - it might pay you to make up a small dummy pour before you tackle the big one. At least you would get to see how it will really look, even if it is in miniature.
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Old 05-12-2009, 09:39 PM   #132
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my kitchen reno - complete remodel (with concrete countertop)


yes indeed, i am following fu-teng cheng's books and videos (i have them all). his first book/video edition came out a few years ago and it is by far the best.

i thought about a trial run, to perfect the technique & also to check the colour.. but .. that would go against my "rock'n roll" renovation style; its all or nothing with me. besides, concrete is cheap. if it looks like crap i'll just smash it with a sledge and bury it in the backyard

ps. finished oven install, fridge install & now working on dishwasher install. will continue with countertop mold making this weekend.
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Old 05-12-2009, 11:55 PM   #133
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Can't wait to see how it comes out - DEFINITELY looking forward to that part!
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Old 05-13-2009, 12:18 PM   #134
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my kitchen reno - complete remodel (with concrete countertop)


Hi,

Just found your thread last week. Great work, and thanks for posting the updates here! That floor is simply amazing and will serve as a nice reminder of everything you've put into the kitchen. Can't wait to see the countertops also. What a great combination of old & new you will have.
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Old 05-30-2009, 09:53 AM   #135
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my kitchen reno - complete remodel (with concrete countertop)


Pour Table Construction:

i chose to make a simple table because i just happen to have the material for it around the yard. this table is different than recommended in the book.. but the required characteristics are the same, a) sturdy b) dead flat c) level.

here i just used 2x6x10 pieces of lumber blocking to ensure sturdiness. some of the blocking is horizontal because the wood was wider than the long 2x6x10 pieces (different batch of wood?). strange. i just put those pieces in horizontal because i didn't want to upset the levelness of the platform.

building a pour table this way is easy, but the thing is HEAVY. i should have built it in the area i plan on pouring the cement so i don't have to move it. ah well.




using a white strip of melmine (part of the mold making piece) to provide a alignment so i can draw a line and countersink some screws into the ply.




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