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Building Custom Countertops

The kitchen counters are being installed, but need to be crafted on site since they were too large for the high-rise elevator. Brad Brewster of Princeton Custom Cabinetry explains that one set of counters was prefabricated at the shop, then brought to the apartment in pieces. The installers make a field joint to bring the two sections together, first by applying contact cement to the two edges, then angling the edges together so that the Formica seam forms tightly as the counter is lowered into place. The counters are then secured with screws from underneath. The second part of the installation requires on-site assembly. The condo's long kitchen counter ends in a round dining center. The entire installation will be done with one large piece of Formica that is 5 foot by 12 foot, making a seamless surface down the entire length of the counter. For the specialty rounded counter, Princeton Custom Cabinetry uses a Verola plywood from South America that is strong and provides a stable undercore for the suspended counter. Once in place, a stainless steel post will serve as a leg for the rounded counter, giving it extra support. The plywood is covered with contact cement that is allowed to dry for five minutes. Spacers are then laid across the face of the plywood so that the Formica can be positioned correctly without getting stuck to the adhesive before the crew is ready. Ernie Wernecke removes the last spacer showing Bob how a tight consistent seam is made using this technique.
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Building Custom Countertops

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" So brad the kitchen counters are. Bake this is -- U shaped it's a very good sides kitchen job here Bob and because we're and high rise and we have to work with elevators therefore we have to bring the countertop -- pieces. So what we did is we prefabricated these two sections in our shop and we brought him together what Ron's getting ready to do is do what we call a field joint. And that's where we will fit together these two pieces of the countertop and once we get it together will swing it into place -- could you just do that in the corner. Well we have a problem with the with this type of a corner with the lazy Susan over we don't have access to the underneath side of the top yeah and when you make a field joint you need to. Screw from the bottom sides and therefore that we will do it and we're fortunate enough in this setting we can put together and then move it into place this is a lot easier to do it this way dissidents right so we're using contact traditional contact cement here. Yes you apply contact cement to both sides of the countertop you do need to let it dry for about five minutes. And then you slide those pieces together and it gives you a tight joint but then you also reinforce that by screwing it from the bottom side all right. All right so the problem here is that you have only one chance to put it there you. -- way you want to help her. Right once that contact grabs the other surface than it's hard to move it around there's not a lot of play with contact cement. -- need to get a nice tight fit right from the start. Exactly. So you butt it at an angle and you bring it down. You don't always have that benefit but here we do because we've got a little bit of room to work -- so that what it is is you let the mica touch first meeting and then you lay it down and that way your joint at the top stays real close when -- have to bring them in level sometimes it catches and you can't slide those two pieces together. And now the roller basically. He finishes up compressing. The laminate onto the glue and then the next thing to do is to drive some screws. Into the substrate from the box. Bravo. Now again another one to do over here. Since we have another joint here that will be building this entire top again back to the situation with the elevator this top is so large that we have to build it in place that the house now the real work begins. All right so this is the circular part of the countertop. And we're going to be attaching it here. I guess you'd call this a scab right guys to justice OK and then we will simply drill from the underside. And this has got to be the most ambitious right brad -- you've got one big sheet of Formica. Yeah actually the largest piece of Formica we are using for this particular part of the job. Bob minutes Bob five by 125 feet by twelve feet and that we will be able to lay this entire area out and it will be seamless. What -- what is this threat. This is overall plywood which is an interior grade of plywood that's out of South America yes it's sustainable resource. Plywood makes excellent underscore for the for the countertops a lot of a lot of -- But in this particular case the plywood gives us that extra strength OK. Now -- driving screws from the underside which will technically. Hold it eventually when we finish this -- we're gonna add a steel. Tubular steel leg here. Right we have a stainless steel post we'll go right down to the finish flooring not a give some extra support for the outside of that top all right. Once the countertop has been assembled and secured down to the cabinet boxes. We are applying a coat of contact cement. Then we'll again have to wait about five minutes for -- to drive before we can go any further whether it. And now brad at this point what you're doing involves. Placing spacers right -- what these what these sticks allow us to do Bob is to position the mica. As you know so that does not attached to the -- because if it does come in contact as we've talked about earlier it will stick and you still remember it's totally unforgiving correct and so this will allow us -- over at this point. And the corner this is the most important part we have an overlap everywhere else around. The perimeter of the top right here's where we need to make sure we have a nice tight fit exactly OK can we bring it -- and you can actually touch. The underside of the laminate which has the contact cement on its dry. Okay just a little push. There you go the other way. Sources of slick. Floor that. -- come to me. Okay. -- Okay."

" Isn't. All right so we've actually made contact down here what you're doing over here. OK I'm holding the seam down tight because I need to remove this last stick on this section. Because that there's our little honk or wave yeah I can see it right here yes when I remove -- stick we will be able to. Press the mica seam down. And only just. Keep an art and on the market that it doesn't flip over okay. And that's -- you get a tight. Consistent. Seeing exactly."

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