DIY Network

Kitchen Restoration: Countertop Construction and Installation From "Classic Rides" episode DCLR-206

In this segment host Kevin Tetz constructs a new countertop for the project '70 Airstream made out of medium-density fiberboard (MDF) covered with a vintage "boomerang" design laminate. The countertop is trimmed with '50s soda-shop style metal trim molding.

The old countertop was in sad shape, and Kevin decided...

to correct the square corners (seen here) and round them off.

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	Figure A
	Figure B

Constructing the Countertop

1. Create a cardboard template (figure A) for the new countertop and cut out the openings for the new appliances.

2. Cut a grove in the edge of the countertop, which will hold the '50s style molding into place. It's held into place with a serrated edge.

3. Apply another layer of wood to give it the correct thickness and an even surface to mount the molding.

   Note: Kevin chose to go with a plastic laminate with a unique design (figure B--red ebony boomerang) for the kitchen countertop.

4. You can cut the laminate with a variety of tools. Kevin uses a pair of electric shears. Cut on the backside of the sheet because the shears can leave a mark on the laminate.

5. The laminate will be trimmed once it's glued to the countertop, so leave about a 1/4" excess from the cut line.

	Figure C
	Figure D
	Figure E

Installing the Countertop

1. To install the countertop Kevin uses contact cement applied with a roller.

2. Apply to both mating surfaces. Wait until both surfaces are tacky before putting them on top of one another.

3. Install rollers so when you lay the laminate down, it doesn't immediately stick to the countertop (figure C).

4. Once you have it where you want it, just pull the rods out. Use a roller to make the laminate free of bubbles and lay properly on the countertop.

5. Use a laminate trimmer to trim the edges of the laminate. A regular router would work with correct laminate trimming bit.

6. To create the metal trim for the countertop, notch out the backside of the metal trim where it meets the corner of the countertop. Put the spine of the trim into the countertop and tap it into place using a soft face mallet (figure D).

7. To form the corner, ease it around carefully so you don't kink the metal. Tap the remaining trim into place.

8. To support the countertop, install a 2x4 ledger board along the back wall (figure E). The countertop fits into place and is secured to the back 2x4 and the front cabinet base.

9. To use aluminum molding up against backsplash and seal it with contact cement, glue to both sides of both surfaces.

10. Apply contact cement to the wall, countertop and both sides of the molding. Once it is tacky place aluminum molding where you want it.

11. Finally, apply caulk to the exposed edges to provide a water tight seal.

Creating the Soda Fountain Look (Web Extra)

• To create the vintage "soda fountain" look, Kevin trimmed the countertop with rippled face molding in satin aluminum.

• To install the molding he used a router to cut a slit in the edge of the MDF countertop.

• The molding slips into the slit and is carefully bent around the corners.

• Kevin also constructed a countertop extension and re-covered the credenza and fold-out dining table in the same vintage boomer rang pattern with metal molding trim.

In the next segment Kevin is joined by Jeff Grigg, a master plumber, to install the sink and fixtures.

RESOURCES :

Dremel Tools
Website: www.dremel.com

Marielle Pull-Out Faucet
Dave Carter & Associates, Inc.
Corp. Office
3530 SW 7th St.
Ocala, FL 34474
Phone: 352-732-2992
Fax: 352-732-6950
Website: www.davecarter.com
OR
Price Pfister
19701 Da Vinci
Foothill Ranch, CA 92610
Toll-free: 800-732-8238

Gas-Electric Refrigerator and Built-In Microwave
Dometic USA
PO Box 490
2320 Industrial Pkwy.
Elkhart, Indiana 46516
Phone: 574 294-2511
Fax: 574 2939 686
Website: www.dometicusa.com

Black Enamel Drop-In Cooktop
Suburban Manufacturing
PO Box 399
676 Broadway St.
Dayton, TN 37321
Phone: 423-775-2131
Fax: 423-775-7015

Water Filter System and Sink Faucet
Hydro Life, Inc.
503 Maple St.
Bristol, IN 46507
Toll-free: 800-626-7130
Fax: 574-848-1400
Website: www.hydrolife.com

Brushed Aluminum Laminate Backsplash
Wilsonart International, Inc.
2400 Wilson Place
PO Box 6110
Temple, TX 76503-6110
Toll-free: 800-433-3222

Formica Laminate Countertop (Boomerang Pattern)
BarsandBooths.com Inc.
200 West Washington St.
Charles Town, WV 25414
Toll-free: 800-507-7632
Fax: 304-728-8465
Website: www.barsandbooths.com

Rippled Face Molding in Satin Aluminum
Outwater Plastics
4 Passaic St.
PO Drawer 403
Wood-Ridge, NJ 07075
Toll-free: 800-631-8375

GUESTS :

Jeff Grigg
Master Plumber
4621 Ellistown Rd.
Phone: 865-689-3999
Knoxville, TN 37924