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Kitchen Pass-Through Karl transforms a clutter-magnet wall into a cabinet and pass-through loaded with storage. From "Wasted Spaces" episode DWSP-203

(Continued from page 2)

With the custom cabinets in place, Karl and Michael rough in a countertop for the pass-through.

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Installing the Countertop

• Measure the combined depth of the cabinets and cut a piece of 3/4" plywood to that width. Cut the plywood to the desired length for the overall countertop – including the overhang past the wall post.

• The plywood for the countertop will slide into place around the post at the end of the cabinets. This will help keep the countertop stable where it extends past the post. Use a measuring tape, pencil and straight edge to measure and mark where to cut out a slot to go around the post.

• Measure and mark a line 1 foot in from each side of the plywood and 1 foot from the post end.

• Use these lines to draw the arcs for the curve at the end of the countertop: Anchor the tape measure where the two lines intersect at one corner of the plywood, hold a pencil against the tape measure at the 1-foot mark and rotate the pencil and tape measure around the anchor point to draw the arc. Repeat for the other corner.
  

  	Figure A
  	Figure B

• Wearing safety glasses, use a jigsaw to cut out the arcs. Hold the jigsaw firmly and guide it by twisting the back of the saw.

• After cutting around the edges, cut the slot from the plywood to slide around the load-bearing wall post (figure A). Don't discard the slot piece.

• Use the plywood as a template to cut a piece of backer board the same size and shape as the plywood.

• Slide the plywood in place on top of the cabinets. Trim the slot piece to fit between the post and the wall, and slip it into place (figure B).

• Use screws to attach the plywood to the cabinets. Drive screws down into the middle (backs) of the cabinets. Also drive screws up through the underside of the four corner brace blocks into the underside of the plywood top. Don't drive screws down through the plywood into the side walls of the cabinets: They can easily split.

• Apply heavy-duty adhesive to the backer board and press it into place, then secure to the plywood with screws. Don't forget to trim and install the long, narrow piece of backer board to cover the slot between the wall post and the rest of the wall.

• Allow the adhesive to cure according to the package instructions.

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