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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 3)

Karl and Michael are almost done creating a stylish pass-through counter and cabinets to replace an awkward, clutter-attracting wall. In the final part of the project, they cut and lay tiles for the countertop, apply grout and complete final trim work.

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Figure A

Installing Tile

• Lay out the tiles for the countertop on the backer board for a dry fit (figure A). Allow an even space between tiles and mark for any needed cuts. If you have trouble getting the spaces even, use small, plastic tile spacers, available in the tile section of home improvement stores.

• To mark for a curved cut, make a template with a piece of scrap cardboard. Position the cardboard on top of the backer board and mark it from underneath. Cut the cardboard along the line, then trace the cardboard onto the tile.

• Pros use a wet saw – which can be rented or purchased – to cut tile. To cut large tiles without a wet saw, use a tile-cutting blade on a circular saw. Always wear a dust mask and eye protection before cutting tile with either type of saw. When cutting the tile, run the blade over the tile several times to get a nice, clean groove.

• If the cut edge of a tile isn't perfectly smooth, clean it up with the saw blade or with some sandpaper.

• Attach a long piece of trim along the perimeter of the countertop. Wrap the wood trim around the entire length of the countertop, attaching it with glue and nails.

• Use a notched trowel to apply mortar over the backer board. Spread the mortar with the flat side, then create grooves in the mortar with the notched side. Wear rubber or latex gloves for easier cleanup when working with mortar and grout.
  

  	Figure B
  	Figure C

• Tap the tiles into place before the mortar begins to dry (figure B). Allow the mortar to cure according to the package instructions.

• Mix sanded grout according to the package instructions. The grout should be about the consistency of cake batter; only mix as much grout as you can apply before it starts to harden. Always use sanded grout when creating wide grout joints between tiles.

• Apply the grout using a grout float (rubber-covered trowel). Make sure to press the grout into all of the spaces between the tiles, then gently scrape away some of the excess with the float.

• Let the grout dry to a haze, then wipe away the excess with a large, damp sponge. Allow the grout to cure according to the package instructions (figure C).

Figure D

Final Trim Work

• Seal the grout with a grout sealer according to package instructions.

• Trim out any raw edges or openings to match the rest of the room. Karl and Michael used 1x6 lumber to build a trim "box" to cover the raw edge where the wall was removed and added other trim around edges and openings.

• Blend the load-bearing wall post to match the rest of the room. Karl and Michael stained and sealed the post (figure D).

• Re-install the cabinet doors and drawers according to the manufacturer's instructions.

• Load up the cabinets and start enjoying this great use for a wasted space!

Now the Spirkos have a great look...

Plenty of storage...

And even space for seating!

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