Time: 20 hours over two days. Difficulty Rating: This project rates a 4 on the Weekend Handyman scale.
Materials: Sink
Butcher-block counter
Tile Tools: Heavy-duty router with straight bit and round over bit
Reciprocating saw with bimetal blade
Circular saw
Impact driver
Tube cutter
Basin wrench
Grinder Day Two - You may need to cut the counter. If so, make careful measurements.
Tip: A lot of times the temptation is to try to measure the entire length with a tape, and inevitably you end up with a bend in the corner and it is hard to get an accurate measurement. Instead, measure to the middle of the wall (figure A) and make a mark at any number that ends in zero and then measure from the other end to the same mark. Find the number and add the two dimensions together to get the exact length. - Rig up a straightedge and block off the walls for dust. Cut the butcher block to length with a circular saw and a 60-tooth carbide tip (figure B).
Tip: Have a helper hold the cut off piece called the "drop." - Take the measurements from the center of the sink and transfer it to the counter. You need a 5/8 reveal around the sink.
- You need two lines (figure C), one for the rough cut with a circular saw and the outside line is for the finished cut with router.
- Make side cuts -- use the clamps as a stop.
- Practice on a piece of scrap wood and then make the plunge with a circular saw.
- Cut the back.
- To finish rough cutting, use a jigsaw to make clean cuts into each corner.
- Use a router (figure D) for the finished cut with a 1/2" on three passes.
Expert Tip: When routing, move the router in the same direction as it spins. - After the straight cut, go back around the opening with a round-over bit for a smooth finish.
- Smooth the edges with some fine sandpaper.
- Seal the open edges with heavy-duty urethane.
- Transfer the holes from the sink to the counter.
- Drill four holes in the counter for the faucet and sprayer with a forstner bit (figure E).
Expert Tip: The forstner bit is stronger and more accurate than a spade bit and easier to use than a hole saw because it removes all the wood in the hole. Hole saws can also get stuck in this really hard wood.
RESOURCES :
Butcher Block Counter Top (Michigan Maple Block)
Brand Name: Wood Welded
Model Number: 144 x 25
Product Information:
- Butcher-block counters are coated with an acrylic finish, which does not require any maintenance.
- Bring butcher-block into your home a couple of days before cutting in order to acclimate it.
- You can butcher-block with any circular saw, just make sure you use a 60-tooth carbide blade.
Michigan Maple Block
Petoskey, MI 49770
Phone: 231-347-4170
Butcher Block Island Top (Michigan Maple Block)
Brand Name: Wood Welded
Model Number 48 x 36
Available: Local Home Centers
Product Information:
- Butcher-block counters are coated with an acrylic finish that does not require any maintenance.
- Bring butcher-block into your home a couple of days before cutting in order to acclimate it.
- You can butcher-block with any circular saw, just make sure you use a 60-tooth carbide blade.
Michigan Maple Block
Petoskey, MI 49770
Phone: 231-347-4170
Dickinson Apron Front Kitchen Sink (Kohler)
Brand Name: Kohler
Model Number: K6546-40-0
Color: White
Kohler Co.
Website: www.us.kohler.com
Revival Kitchen Sink Faucet (Kohler)
Brand Name: Kohler
Model Number: K-16109-4A-BN
Color or Style: BN
Kohler Co.
Website: www.us.kohler.com
Travertine Tile (Rubble Tile Distributors)
Brand Name: Country Floors
Model Number: 18 x 18
Color or Style: Ivory Travertine Unfilled Limestone
Rubble Tile Distributors
Minnetonka, MN 55345
Phone: 952-938-2599
Fax: 952-938-8045
Website: www.rubbletile.com
Renovating a Kitchen (For Pros By Pros Series)
ISBN: 1561585408
Author: Fine Homebuilding Editor
Order this title from Amazon.
The Taunton Press Inc.
Website: www.taunton.com
Kitchens: Plan, Remodel, Build
ISBN: 1580110495
Author: Creative Homeowners Press Editor
Order this title from Amazon.
Creative Homeowner Press
Website: www.creativehomeowner.com
GUESTS :
Pat Stanley
PO Box 245
1420 Standish Ave.
Petoskey, MI 49770
Phone: 231-347-4170
Tollfree Phone: 800-678-8459
VP Sales
Michigan Maple Block
Laura Roenitz
444 Highland Dr.
Kohler, WI 53044
Phone: 920-457-4441
Sr. Market Analyst
Kohler Company
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