Daveney. Kitchen Countertops. May 05th , 2017.
Making your own concrete countertop is one of the more challenging—and rewarding—DIY projects. If you’re a rookie, keep your goals simple. Plan for basic color treatments and plain edges, and also plan to spend a few weekends on the project.
This project is a simple, 2' x 6', 2" thick countertop island with a smooth surface and a cutout for a square cooktop.
Create the Mold
To determine the size of your countertop, measure the base cabinets or your existing countertop. If measuring the base cabinets, add an extra 3/4" for an overhang. Our island countertop will be 3’ x 4’.
The key to a great countertop is a well-built mold to pour the concrete into. Start with a 4' x 6' piece of 1" thick melamine particleboard. Set firmly on a pair of sawhorses. Measure and mark the exact dimensions on the mold base, then cut using a circular saw (image 2).
Cut the sides of the mold. Measure and mark four 2-3/4-inch strips. Use a table saw to make the cuts. Each strip should be 4-feet long.
Then attach the sides by drilling 2-inch pilot holes every 6 inches. Join two of these 4-foot strips to the 4-foot sides of the base, using two-inch wood screws. Trim the ends strips and attach them in the same way to the remaining sides of the mold. Use a square to check corners, and the outer mold is complete.
Make Cutouts and Add Sides to the Mold
If you need to have a cutout in your countertop for a cooktop or sink, measure and mark it on the mold's base. To start the cut, drill pilot holes on the inside corners of the portion that will be removed. Then insert a jigsaw into the holes and cut from hole to hole along the edge marks.
Then measure and cut the sides for the cutout, attaching them by butting them against the edges of the base inside the cutout.
Carefully clean the mold of sawdust and other materials. The bottom of the mold will be the top of the countertop, so it’s important the concrete sets on a debris-free surface.
Run a small uniform bead of 100-percent silicone caulk in all the inside corners and seams of the mold. Smooth the bead with a caulk tool and let dry thoroughly for 24 hours. You can also use the tip of your finger to smooth out the caulk. The silicone will seal the joints of the mold and prevent the wet concrete from leaking.
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