DIY Network

Upscale Kitchen Island: Building the Countertop From "Weekend Remodeling" episode WKR-213

	In this week's episode of Weekend Remodeling, host Fuad Reveiz builds an upscale kitchen island ...
	that features counter-to-ceiling columns.
	This particular kitchen was a perfect candidate for an island because of the ample open space.
	In this segment Reveiz shows you how to build a laminate countertop.

In this segment of "Upscale Kitchen Island," host Fuad Reveiz builds the countertop by measuring the cabinets to determine the countertop size. He then measures and cuts the particleboard, applies laminate to the board and sands the countertop to remove any sharp edges.

This is an intermediate level project and rated 3 on a "difficulty" scale from 1 to 5, with 5 being the most difficult.

Materials and Tools:

base cabinets
particleboard
laminate
contact adhesive
1 x 6 wood
beadboard
base molding
crown molding
corner molding
screws
latex paint
router
table saw
miter saw
circular saw
level
palm sander
several clamps
disposable paint brushes
brad nailer
trim nailer
framing nailer
belt sander
laminate roller

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	Figure A
	Figure B
	Figure C
	Figure D
	Figure E
	Figure F
	Figure G

Building the Countertop

1. First, determine the size of the countertop, including the 1-1/4" overhang needed. Then mark and snap a chalk line on the particleboard.

2. Clamp a straight edge to the board to make sure the cut is as close to perfect, then with a circular saw, cut down the length of the straight edge (figure A).

3. Use a leftover piece of particleboard and cut the same width as the countertop. Apply some wood glue and then with the trim nailer, attach it to the end that will eventually become the overhang.

4. Cut some 3"-wide strips (figure B) that are glued and nailed into place in order to double up the bottom edge so it will hold the laminate that will be attached later.

5. Use a jigsaw to round off the end that's going to be the overhang (figure C).

6. With the particleboard ready to apply the laminate, it's time to actually cut the laminate. Be sure to cut it a little larger than the particleboard so you can route all the edges nice and flush.

7. Clamp the laminate to the 2 x 4s to hold it steady while you cut the strips that will be the edge pieces. The top gets cut the same way.

8. Use a disposable brush and apply contact cement to the edges of the particleboard and to the back of the laminate strips.

9. Once the contact cement is dry to the touch begin applying the laminate to the edges of the particleboard (figure D). Let it overlap on the top and bottom and carefully work your way around the edge.

10. When the entire edge is attached use a laminate roller to make sure you have good contact between the laminate and the particleboard.

11. Using a trim router and a flush-cut bit, route the top of the laminate flush with the surface of the particleboard (figure E).

12. Flip the board over and repeat the same process on the back moving carefully down the edge until both sides are routed flush.

13. Once the sides are complete, apply the contact cement to the back of the top piece. Set the top piece aside to dry while you apply cement to the surface of the particleboard.

    Safety Alert: If you are applying the adhesive indoor make sure to have proper ventilation.

14. With the cement dry begin placing some wooden dowels, which you'll need to prepare beforehand, onto the surface of the particleboard. The dowels need to be no more than 4" or 5" apart (figure F).

15. Place the laminate on top of the dowels, and starting at one end remove one dowel at a time, carefully applying the laminate to the particleboard as you go.

16. Continue checking the overlap on the sides as you move down the laminate until, finally, you remove the last dowel and the laminate is applied. Use a roller to make sure the surfaces are making good solid contact.

17. Route the sides with a flush-cut bit, carefully working your way around.

18. Finally, finish it off with a small round-over bit (figure G) that smoothes the sharp edges.

    Note: You can use fine-grit sandpaper to smooth the edges if you don't have a round-over bit.

In the next segment our host installs the finished countertop and builds some columns for the new kitchen island.

Next: Installing Countertop and Building Columns