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  • Outdoor Kitchen: Stone Counter-Veneer
  • From "Build an Outdoor Kitchen"
    episode DBOK-103


    In this segment of Build an Outdoor Kitchen, work begins on custom-cutting the stone and installing it onto the outdoor-counter surfaces.

    Materials:

    mortar
    fiberglass mess seam tape
    circular saw with carbide blade
    hammer
    chisel
    level
    circular saw
    carpenters square
    lag screws
    grout bag
    grout
    trowel
    soft cloth
    hammer drill
    safety glasses
    dusk mask

    Safety Alert: Wear a dust mask when cutting stone veneer since the process will create a lot of airborne dust.
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    Cutting and Installing the Blue-Stone Veneer

    • The blue-stone veneer is cut using a specialized saw and a carbide blade (figure A). You'll begin by marking and cutting a scribed a line down the stone. Continue the scribed line across the edge, then flip the stone and transfer the scribed line so that it continues on both sides of the stone.

    • Once the scribed line has been made all the way around, the stone can be split along the scribed line with gentle taps of a chisel (figure B).
    Photo

    Figure A

    Photo

    Figure B


    • Once you've marked your stone, carefully cut along your marked line using the saw with the carbide blade (figures C and D).
    Photo

    Figure C

    Photo

    Figure D


    • Once you've cut your scribed line all the way around the stone, gently tap inside the groove with the tip of a chisel to cleanly split the stone (figure E).

    • Once all of your stones have been cut, you can begin setting it using thin-set mortar. Before placing the stone, 1/2-inch wooden blocks are laid along the perimeter of the cabinet (figure F). The shim blocks help in support the stone in place as the mortar sets, and provide the 1/2-inch gap that will form the grout line.
    Photo

    Figure E

    Photo

    Figure F


    • Start the stone-laying process by mixing some thin-set mortar. Since this mortar sets up quickly, mix up only enough to set one or two stones at a time. Spread a thin layer of mortar over the entire back surface of the stone (figure G) and the portion of the counter wall where the stone will be positioned (figure H).
    Photo

    Figure G

    Photo

    Figure H


    • Once the mortar is applied, carefully lift the stone into position (figure I). Once it's in position, move the stone slightly back and forth to solidify the mortar seal, and check the final position.

    • Applying stone veneer (figure J) is not difficult. Just remember to work on just one or two stones at a time. In that way, you can plan and custom cut the stones you need as you work, and it will prevent excess mortar from setting up to early.
    Photo

    Figure I

    Photo

    Figure J


    PHOTO

    Figure K
    • Because spacers can't be used to position the pieces of stone that run along the top of the cabinet unit, you'll need to create a lentel to hold the upper stone in place. We created ours out of a sheet of aluminum. Using deck screws, fasten the piece of aluminum lentil around the cabinet openings (figure K). This will provide a ledge for the stone to rest on.

    Important: Included in this episode are the steps in this outdoor home-improvement project as shown in the episode. These steps are general guidelines that are applicable for similar construction projects. For any construction projects, there may be procedures, specifications, equipment, etc. that are specific to the specific site and circumstances. There may also be variations according to the type and brand of materials you select. Always consult local building codes when undertaking significant home-improvement projects, and read and follow the manufacturer's directions and precautions that come with any materials, tools or equipment you decide to use.

    In the segment that follows, work continues on laying the stone veneer and building the kitchen bar.

    Next: Stone Veneer and Bar Framework

  • ALSO IN THIS EPISODE: