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post #91 of 281 Old 09-14-2009, 01:40 PM
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Pass the popcorn, and DOWN IN FRONT!!



EDIT: Crap, how am I supposed to watch the cement drying when it's back on the previous page?!?

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post #92 of 281 Old 09-14-2009, 03:31 PM - Thread Starter
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Yup, here in Georgia we get excited watching concrete dry, the grass grow, chrome rust, paint dry.......

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post #93 of 281 Old 09-15-2009, 06:38 PM
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curious to see how this turns out. this whole concrete counter thing is pretty intriguing, especially considering I know what I spent on granite...
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post #94 of 281 Old 09-16-2009, 06:30 AM - Thread Starter
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Quote:
Originally Posted by smakovits View Post

curious to see how this turns out. this whole concrete counter thing is pretty intriguing, especially considering I know what I spent on granite...


I think I've gone through all my patience, and I'll take the mold off and flip the top today at lunch. One of the benefit's of working from home. Although I'll hold off polishing until Sunday so today's pictures won't be the final product, that way the concrete can fully harden. Don't judge me too harshly until the polishing is complete.

For an awesome looking concrete top check out mmeister's thread...

http://www.avsforum.com/avs-vb/showthread.php?t=1151574

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post #95 of 281 Old 09-16-2009, 07:47 AM
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We'll be here waiting for the first unveiling photos; and will be nice ( I promise) at least until the polishing is done :-)

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post #96 of 281 Old 09-16-2009, 09:43 AM - Thread Starter
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Gee thanks Cuz... I was delayed in removing the top from the mold. Apparently my wife said she'd kick my a$$ if I didn't wait for her to be home and watch. I guess she's excited too, talk about a high WAF!

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post #97 of 281 Old 09-16-2009, 12:05 PM
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And HIGH WAF >>> that's a beautiful thing
OK we will col our heels and wait for the Mrs.

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post #98 of 281 Old 09-16-2009, 12:30 PM
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Quote:
Originally Posted by cane.mba View Post

I was delayed in removing the top from the mold. Apparently my wife said she'd kick my a$$ if I didn't wait for her to be home and watch.

I don't care what any of these other guys might be whispering behind your back about being hen pecked, I say you're still the king!!


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post #99 of 281 Old 09-16-2009, 04:46 PM - Thread Starter
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Out of the mold...



Right side looks really good, this is the side I thought I added too much water to the mix on...



Looks like I'll be mixing up the slurry to fill the bubbles. A few I could live with but there are simply too many and several that are too large. The sink area also has too many bubbles, although I had planned on using the slurry to fill even small bubbles on the sink rim.







I'm happy with the 45 degree angle, it came out nice and sharp.




Overall I'm very happy, a little slurry, a little grinding, a lot of polishing and this should come out pretty awesome. I think I'll do the slurry tomorrow and then start the finishing process on Sunday.

Thanks,

Mike

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post #100 of 281 Old 09-16-2009, 06:26 PM
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Looks sweet man I am very impressed. A little slurry, a little grinding and a little polishing and it will look spectacular....are you taking orders yet??

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post #101 of 281 Old 09-16-2009, 06:49 PM - Thread Starter
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Thanks! Sure but shipping and handling will kill you I have three more of these to make so hopefully by the third I'll have the process down to a science. This one didn't come out quite as well as I would have hoped. I'm still pretty happy and not running out to price granite just yet.

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post #102 of 281 Old 09-17-2009, 05:54 AM - Thread Starter
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Quote:
Originally Posted by hanesian View Post

I don't care what any of these other guys might be whispering behind your back about being hen pecked, I say you're still the king!!



Hen Pecked..? Nope, I just keep making enough progress with my build that my wife hasn't lost all hope. With enough momentum she's excited about seeing all the little details pulling together.

Although she's probably not this excited..


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post #103 of 281 Old 09-17-2009, 06:57 AM
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Mike,

I forgot was this your very first shot (or did you experiment on a smaller scale first) ?

Either way; this looks VERY encouraging - you might just have signed me up for my next BIG project.

A kitchen redo is on my honey-do list, next year, or maybe....
Keep in mind that my one year basement will be finished by (Thanksgiving - I hope) the 30 month point...

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post #104 of 281 Old 09-17-2009, 07:42 AM - Thread Starter
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This is my first real shot. I did a 2' x 2' square before, to familiarize myself with the process and test colors, polishing, etc. However, it's much more stress when things have to line up and it's actually being made to specific dimensions.

However, that being said I just tested my knockouts for the faucet and soap dispenser and everything looked perfect. WHEW! The part I was worried about was that the hole on top had to be small and then hole on the bottom had to be larger. The water lines run down, and then there's a big "bolt / flange" that has to fit and hold. It did!!! Ok so now I'm much more happy with the product so far! I was reading the manual I need to wait a couple more days before I start the slurry. You have to polish to at least a 400 grit pad before patching the holes. That makes sense as you expose more bubles during the grinding and polishing phase. Then once the slurry is applied (Portland cement, color, and water mixed to a toothpaste consistency) you have to let it cure for 36 hours before resuming the polishing process. So I'll polish and slurry on Sunday. Then final polish and move the counters inside Tuesday / Wednesday next week.

Ok now I'm excited!! This really has been pretty easy. I've wanted to do this for a couple of years but I've never done anything with concrete before so it was a little intimidating. Mmeister's project thread encouraged me to do it, and I'm glad I did.

Once this top is complete I have to do my bar top. Which I think I'm going to include stained glass cobbles in the top and light them from underneath.

The next top will be for my back bar area or my BigMouth inspired theater bar. So total three more once this one is complete.

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post #105 of 281 Old 09-17-2009, 09:54 AM
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Looks great!

Yea you have to really get in there with your hands and work those edges around the sink. You can even vibrate the sink mold to get some bubbles out.

I'd take some sandpaper and sand the edges now while it's still "soft" around the sink. You will find that it is a pain in the arse to get in there and wet polish so if you can fix any problem areas in there, now is a good time.

How did the split turn out?

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post #106 of 281 Old 09-17-2009, 10:37 AM - Thread Starter
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Quote:
Originally Posted by mmeister View Post

Looks great!

Yea you have to really get in there with your hands and work those edges around the sink. You can even vibrate the sink mold to get some bubbles out.

I'd take some sandpaper and sand the edges now while it's still "soft" around the sink. You will find that it is a pain in the arse to get in there and wet polish so if you can fix any problem areas in there, now is a good time.

How did the split turn out?

I'm so thankful I decided to split the top. Man just flipping it one section at a time was killer, at 320lbs total (160lbs per section) there's no way I would have been able to flip it, let alone carry it in and place it. I think I can move the sections on my own, but time for my buddies to step up for a few minutes I'd prefer not to have get a hernia.

I had thought I added too much water to the right side of the mold. However, it turns out that side was the best looking right out of the mold. Went back to Cheng's book and he said the mixture should be like runny oatmeal which the right side was. So now for the next top I won't freak and add more water to get the right consistency. It was much easier to work as well.

Thanks,

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post #107 of 281 Old 09-17-2009, 01:57 PM
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Yea, you need to keep the mix loose (I think I talked about it on my thread but I'll have to reread and add it if I didn't). If it's too thick the bubbles wont want to move but, if it's too runny the mix will not be as strong and you run the risk of cracks. You have probably read about the use of a water reducer that makes the mix loose without adding as much water. He sells it on his site and you can find it on ebay sometimes also. I need to update my thread with some pics and thoughts of some of the finishes I've tried since.

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post #108 of 281 Old 09-18-2009, 05:52 AM - Thread Starter
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Quote:
Originally Posted by mmeister View Post

Yea, you need to keep the mix loose (I think I talked about it on my thread but I'll have to reread and add it if I didn't). If it's too thick the bubbles wont want to move but, if it's too runny the mix will not be as strong and you run the risk of cracks. You have probably read about the use of a water reducer that makes the mix loose without adding as much water. He sells it on his site and you can find it on ebay sometimes also. I need to update my thread with some pics and thoughts of some of the finishes I've tried since.


I think the sand and proper amount of water mix is the key. The reducer is probably great, but I just have a hard time buying it for some reason. I guess if it was in the local store I might try it. Let's see more pics, I revived your thread for you so let's see some updates!!!

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post #109 of 281 Old 09-18-2009, 06:00 AM - Thread Starter
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Fear the past, Envy the Future!

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post #110 of 281 Old 09-19-2009, 09:42 AM
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Quote:
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I think the sand and proper amount of water mix is the key. The reducer is probably great, but I just have a hard time buying it for some reason. I guess if it was in the local store I might try it. Let's see more pics, I revived your thread for you so let's see some updates!!!

Thanks for the revive!

I found the water reducer local but I found they only sell it in large amounts here for commercial use I guess. Thats why I went the sand/cement route. Is Sunday the big day?

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post #111 of 281 Old 09-21-2009, 07:18 AM - Thread Starter
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Well I partially polished the counter. We're going on 10 days of rain, and looks like no break until next Monday so without any Sun my energy level is waning. However, I started polishing with the 100 grit pad and light pressure, then worked up to the 400 grit pad and finished one section. Turns out my wife likes the look of the practice top with all the rock exposed. So I need to slap the 50 back on and start over, then work up to the 400 grit, add the slurry to fill in the holes, then work it from 100 up to 1500.

In the mean time I added a few slate tiles under where my dishwasher will be. Not pretty, but I just wanted to level the surface as much as possible.

Washed out weekend...

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post #112 of 281 Old 09-23-2009, 06:13 AM - Thread Starter
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I've been slurried, No Hanes not my speech. Although if you ever make it down to Atlanta I'm sure there will be some slurred speech.

It finally stopped raining in Atlanta and I was able polish the counters to a point where I could apply the slurry to fill the bubbles.

The Slurry mix was just portland cement, dye, and water mixed to a consistency of modeling clay or thick peanut butter. Then you just work it into the surface like wood putty.











Now more waiting.. Takes 36 hours to dry and then I can polish and seal the counters Thursday. Hopefully I can get them installed on Friday evening.

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post #113 of 281 Old 09-23-2009, 06:23 AM
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Slurry to the rescue!! Cleaned up nice. Did you make any headway on the stainless steal?

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Quote:
Originally Posted by mmeister View Post

Slurry to the rescue!! Cleaned up nice. Did you make any headway on the stainless steal?


Haven't looked yet, honestly I've been so stuck in the process I haven't thought that far ahead.

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post #115 of 281 Old 09-23-2009, 03:17 PM
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Quote:
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Slurry to the rescue!! Cleaned up nice. Did you make any headway on the stainless steal?

Haha, I just noticed steal instead of steel. It was a long night. Go steal some steel!

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post #116 of 281 Old 09-23-2009, 03:27 PM - Thread Starter
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That's funny, I never noticed either... I'm going to call a few metal fabrication places around me tomorrow. Since I only need two pieces 2" x 3" it shouldn't be too hard to find someone with scrap that would shape them for me.

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cane, very impressive work! I had checked out meister's thread a while back and could not believe all of the detail. And now you've put all that into yours .
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A great big spirit cheer for you and your slurrying, dude!!!


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post #119 of 281 Old 09-24-2009, 06:00 AM - Thread Starter
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Thanks!!! I'm pretty excited! I plan on finishing the polishing process tonight, and hopefully get it sealed so that I can install it tomorrow!

Whoo Hoo!! Then I'll start the bar top!

Thanks,

Mike

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Mike,

Wow that "slurry" process really made a difference!
Looking forward to seeing polished photos

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