DIY Network

Airstream: Install New Countertop From "Classic Rides" episode DCLR-205

In this first segment of the "Bedroom" episode for the 1970 Airstream restoration, host Kevin Tetz adds some light and modern styling in the dark bedroom by recovering a dated laminate countertop with aluminum sheeting. The process includes using a metal bending brake to create the lip of the countertop.

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Note: The project Airstream, which is an "Overlander" International Land Yacht is a double, which means a double bed (really a 3/4 bed rather than a twin bed in the sleeping area).

The project Airstream features a double bed.

The trailer is brought into the 21st Century with a unique countertop.

	Figure A
	Figure B
	Figure C

Installing the New Countertop

1. For the new countertops, Kevin covers them with aluminum sheeting, which is available at hardware stores and home centers.

2. Measure the dimensions of the countertop onto the aluminum sheeting, plus 11/16" for the lip of the counter.

3. Lay down tape over the cut lines to protect the surface of the aluminum.

4. Using an electric shear, line the inside edge of the shear up with the cut line (figure A).

   Safety Alert: When working with metal always wear heavy-duty gloves and eye protection!

5. Measure and mark the bend line for the countertop. To create the bend use a metal bending brake (figure B), which can be rented. Insert the countertop into the backside of the jaw. Be sure to protect the metal where it bends by taping it down.

6. Now line the marked line up to the jaw with your thumbs. Clamp it down and create the 90-degree bend. Move the jaw up and down slowly so it does not over bend, and add silver plastic trim (figure C) to the lip of the countertop.

7. To install the countertop to the Airstream, first mask off surrounding areas with paper to protect it from adhesive overspray. Spray a light, even coat of adhesive to the backside of the aluminum. Then do the same to the existing countertop in the coach.

8. Maneuver the piece into the area without getting into contact with the adhesive sides, then once it is in place, press down firmly so the aluminum sticks to the countertop.

9. Finally, run a bead of caulk along the upper edges of the aluminum, creating a seal between the side walls and the aluminum.

Bending Brake

Metal Bending Brake (Web Extra)

Metal forming tools are available through specialty tool retailers like the Eastwood Company, Harbor Freight, home centers and can often be rented from metal working supply companies. The tool Kevin used for our aluminum countertop, a bending brake, is a very simple design and easy to use. Bending brakes come in a variety of sizes from modeling brakes up to industrial bending machines. There are also different pliers with a wide bill that can be used for bends on narrow sections of metal.

If you don't have access to a metal bending brake, you can do the job manually by clamping the metal sheet to the top of a counter or work table. Then use a 2x4 and gentle even pressure against the table's corner to create a straight, 90-degree bend--or any angle you desire. For a rounded corner, use a wooden dowel or metal pipe and bend the metal slowly over the rounded surface to create the curved bend.

Always wear appropriate safety equipment and be patient when forming metal. Metal has a dense molecular structure that doesn't want to move around quickly--it wants to spring back into its formed "cell memory position". It's a good idea to practice with scrap metal before working on your specific project.

In the next segment Kevin etches a fun design into the glass top for the new countertop.

RESOURCES :

Brushed Aluminum Mini-Blinds 1/2" Slat Light Lines
Hunter Douglas Window Fashions
2 Parkway, Rt. 17 S
Upper Saddle River, NJ 07458
Toll-free: 800-789-0331
Website: www.hunterdouglas.com

Pleated Folding Door
United Shade, LLC
28605 C.R. 6
Elkhart, IN 46514
Phone: 574-262-0954
Fax: 574-262-0908
Website: www.unitedshade.com

Bed Cushion
Restored in lush faux leather
Ultra Fabrics
Ultrafabrics, LLC
400 Executive Blvd.
Elmsford, NY 10523
Phone: 760-745-7621
Website: www.ultrafabricsllc.com

Decor Tambour in Brushed Aluminum Veneer Winona Manufacturing
24 Laird St.
PO Box 1283
Toll-free: 800-826-2687
Website: www.winonamanufacturing.com

Portable Blasting System and Restoration Supplies
Eastwood Company
The Easthill Group, Inc.
265 Shoemaker Rd.
Pottstown, PA 19464
www.eastwoodco.com

Classic Rides Logo
Randy Russell
Russell's Signs
308 Mill St.
Pulaski, TN 38478
Phone: 931-363-6679