DIY Network

Building a Frame Support for Sink From "Kitchen Renovations" episode DKTN-408

In this first segment of the third "Rustic Contemporary" episode of four, host Paul Ryan gives a tour at the marble supplier showing the wide variety of stone options and how the slab of marble is fabricated into a sink. Back at the house a frame support is built for the marble sink since it is so heavy.

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	It's hard to believe that this small, dated kitchen...
	is renovated into this spacious,...
	new cabinets, sparkling appliances and unique hardwood flooring!

Materials and Tools for Building a Frame Support for Sink --

Fabricated Sink
Silicone
2 x 4 lumber
4 x 4 lumber
Power drill
Tape measure
Speed square
Pencil
Hammer
Angle brackets
Screws

Materials and Tools for Countertop Installation --

Countertops
Tape
Putty knife
Glue
Suction cups
Silicone
Coloring pigment
Epoxy
Hardener
Caulk gun
Ruler
Pencil
Shim

Materials and Tools for Glass Tile Backsplash --

Glass tiles
Work gloves
Safety glasses
Adhesive
Wet saw with diamond blade
Dry cloth
Margin trowel
Spacers
Rubbing stone
3/16th" square notched trowel
Thinset

Note: Before the work continues, Paul takes a tour of a Midwest tile, marble and granite supplier, where he saw the Guatemalan kitchen-ready marble (figure A) that the homeowners chose for their renovated kitchen.

FYI -- A slab (approximately 1,200 pounds) of marble (figure B) comes from a mountain quarry and is sliced like a loaf of bread. Experts suggest that homeowners go for a particular pattern instead of just the color -- especially since the marble slabs can be so ornate and unusual. Once the stone is cut from a quarry it's polished to a high gloss.

For the "Rustic Contemporary" kitchen in this project, not only will be countertops be made from marble but the sink will be fabricated using the same stone. The bottom of the sink is honed by hand to take it from a shiny to a matte finish. The polishing pads have a diamond grit -- with each pass getting progressively finer. And the buffing process is done under water. Using a laser line as a guide, the saw operator cuts the marble slab with a diamond blade, which gets hot so a jet of water is sprayed on the blade constantly to keep it cool.

Before the next cut the saw operator hoses off the sludge -- the term for the wet stone sawdust. When the pieces are cut for the sink, they're glued and clamped till dry. A computer controlled CNC machine (figure C) is used for any complex cutting such as curves or waves. A single cut can take an hour. This marble is really tough, so even drilling a faucet hole can take a long time.

Figure A

Figure B

Figure C

	Figure D
	Figure E
	Figure F

Building a Frame Support for the Sink

1. Confirm the depth of the sink and measure down an extra 1/16" to allow for the bead of silicone needed to hold the countertop.

2. Draw a line at the proper depth. This is where the sink cross brace supports will go.

3. Cut 4 x 4 lumber (figure D) to size for the braces. Drill pilot holes to prevent the wood from splitting and screw braces into the cabinet.

4. Make 2 x 4 legs (figure E) to sit under the braces. The 2 x 4's will help carry the weight of the sink.

5. Position the 2 x 4's into place and attach to the 4 x 4 cross braces using angle brackets (figure F).

6. Dry fit the sink into place.

7. Once the countertop is in place, silicone the sink in.

In the next segment, the marble countertop is installed and tips are given on mixing epoxy.

RESOURCES :

Countertop and Sink Fabrication and Installation
Credit River Granite
Website: www.creditrivergranite.com

Marble Slab
Brand name: New Verde "G"
Color: Guatemalan Green
Midwest Tile, Marble and Granite
Website: www.midwesttile.com

Glass Tile for Backsplash
Product: Casa California 4 x 4 Field Tile
Color: Cane Irid. #006

Product: Haiku 2.5 x 5 Field Tile
Color: Equator Non-Irid. #137

Product: Terrain Canyon Liner
Color: Equator Non-Irid. #137
Oceanside Glasstile
Website: www.glasstile.com

GUESTS :

Steve Eckelman
President
Credit River Granite
Website: www.creditrivergranite.com

Paul McCabe
Vice President
Midwest Tile, Marble and Granite
Website: www.midwesttile.com