solid surface countertops to clamp everything

As I mentioned a couple weeks ago we got a new surplus solid surface slab online after numerous quotes of $1,000 plus much more.  That sounds equally scary as it actually was.

After buying the slab it sat in our garage for maybe a day and a half before Mike attacked it while using buzz saw.  Before he made any cuts though, he meticulously outlined the cuts however make to acquire all the pieces he needed.  Here is a little diagram that shows the cuts he earned and all of the pieces he needed.  Remember, not merely did we end up needing the particular counter piece and back (and side) splashes, we also needed small slivers, (the pink pieces), to add to each edge to beef up from 1/2" thickness to at least one".  

Since we all know how Mike works, (and how much he loves waiting to do things for me to take pictures), he'd already cut the pieces up and glued everything together, (we're talking a max of two hours while I used to be inside working).

The most notable and right side pieces are the type which is to be exposed hence the additional pieces to fortify the sting.  The wood pieces were glued on for supports the place that the cabinet bases were so it laid flat over the base.

Mike used the additional solid surface countertops to clamp everything right down to ensure even pressure.

This close-up shows how the original slab was 1/2" thick, but by gluing on another piece, it's now 1" and appears a good deal beefier.  (You possibly can barely straighten out line down the seam the location where the two pieces were joined (mostly a result of the shadows), and Mike didn't even do anything whatsoever special except line this with his hands, and after sanding the seam was invisible).

This really is another illustration of the invisible seam.  I am not even sure where it is, but I believe the most notable piece extends out to the side.  Despite the presence of the slight beige piece and white glue, I was surprised at how seamless it looks. 

And, within the spirit of keeping it real, I must zoom out slightly and explain to you what are the results once you cut up solid surface - a huge mess.

It was like shaved ice, but plastic.  Everywhere.  I'm glad I didn't come out until after it absolutely was over, I am able to only think about the cloud of shaved plastic that was generated over the cutting process.  I'm certain goggles along with a mask were worn.  I'm certain.

After flipping the countertop over, another task, (a bit less messy, although obviously loud enough to warrant ear muffs), was routing the side to get the nice edge profile.

After cutting one or two options for me available, I picked small a curved edge with top and left underneath edge square.  We've got both rounded and angular pieces within the room, so we thought having both will be yet another method to tie everything together. 

Here's a close-up of the corner profile that Mike first did to make certain I liked it, (I still could have gone having a larger rounded corner or beveled corner at this time), but I loved it and gave him the go-ahead. Should your wondering the slightly darker lines a good inch in are simply just dirt left over on the router.

Mike had kept the protective plastic for the slab up to this time and I've always had this thing about the plastic covering.  Which i leave it on until it's essential to eliminate it, and if it does not need to be removed, I'll get out until it starts getting dirty on the edges as well.  It drives our kids crazy, (One time i left the plastic on my laptop for any year), but Personally i think like it's officially not new anymore once that plastic comes off.  So, course, I took a photo of Mike ceremoniously removing the plastic for me personally.

As soon as the plastic was gone arrived to start sanding.  Like I mentioned before, we bought a sanding kit that including each of the pads required for matte, satin, or semi-gloss finishes.  I made the choice to settle for a satin finish so it was an easy task to clean, but were built with a more matte finish as opposed to high gloss sinks.

The pink pads above are various grit pads getting the slab to your smooth finish, and the ones above are for having this desired finishes, (gold for semi-gloss, gray for satin, and maroon for matte).

The kit included information about the different finishes and Mike went as a way as specified, to the satin finish it required sanding with 4 different grit pads, then your gray pad, more specifically: 120-grit (120 micron), 180-grit (100 micron), 280-grit (60 micron), 400-grit (30 micron), then the Gray Scuffbrite pad.

Mike first sanded the edges being extra careful to take care of the profiles he just routed.

He then started at the lowest grit pads and worked his way from the sequence one-by-one.

Since every one of the sanding looks exactly the same no matter what grit pad you have, I'll spare you the photos.  And that is good, since after this I stopped taking photos and went inside to try and do other sorts of projects.

Once Mike finished sanding everything, (like the backsplashes), he brought my way through to accomplish a dry fit.  Thankfully everything fit and that we didn't have to scribe the walls, (if your walls were wavy by any means we would - here's a step-by-help case anyone's wondering what I'm speaking about).

The cabinets were already level and didn't require any prep, but we did add extra blocking for the left side since we added a spacer to maneuver the vanity a couple inches in the wall.

To setup, Mike just globed on some sealant on the many cabinet edges plus the blocking within the wall.

Then we manhandled it into place and set it carefully within the cabinets.  We waited a few hours and measured for that sink and faucet holes.  We figured this may be easier minus the backsplash in position.

After double and triple checking our layout, Mike cut the holes.  He used an everyday hole bit and cutting the solid surface is like cutting hard PVC, full of the mess, (that was fortunately contained in the cabinet below).

Following the holes were cut, Mike said he would install the backsplash, and so i found another stuff to do downstairs.  In regards to a around 30 minutes later Mike casually walks by and says don't go ahead the restroom tonight.

Now, we're always doing almost project a single room or other and that we always just step in the insert drying project here ie. newly stained i'm all over this the ground, or deal with the wet paint on the trim, and so i was intrigued in regards to what would render the lavatory completely unusable for the entire evening.

However figured against each other.

To hold on to the backsplash towards the wall, Mike jimmy rigged some supports outside of long components of trim that she had lying around.  He propped them throughout the room, one resistant to the new built in, (which I'll talk a little more about within a future post), as well as the other contrary to the half wall.

Obviously, which has a bathroom downstairs I am not happy to play triple limbo only to make use of the restroom.  Well played, Michael.

Following counters and splashes established, (overnight), we immediately set the sinks and faucets, and sealed the corner relating to the splashes and countertop by incorporating clear waterproof sealant.  Since this essentially brings us as well as the tip line I'll save the complete after photos to the big reveal!  I have some styling and a few painting to end up, but we're calling the project almost done!