How to Build a Bathroom Countertop

Its Getting There

Of all the things that you have in a house, one thing there never seems to be enough of is countertop space. This is especially true in the bathroom. There are several ways that you can build a bathroom countertop in an effort to make it both space saving and practical. Once you learn the basics, it's only a matter of measuring and building the type of bathroom countertop you need.

Things You'll Need

• Table saw
• 1 sheet of ¾-plywood (48-by96-inches)
• Electric miter saw
• Wood glue
• Sanding block
• Hammer
• 3d box nails
• Contact cement
• 1 piece of plastic laminate 2-by-60-inches
• 1 piece of plastic laminate 22-by-60-inches
• Wide paintbrush or roller
• Along the frontage
• Router
• Plastic laminate router bit
• Belt sander
• 100-grit sanding belt
• 6 pieces of ¾ by ¾-inch lumber

Instructions

1. Set the table saw fence at 36-inches over the blade. Place the plywood on the table saw and cut it across the grain. Next, set the table saw fence at 21-inches and rip the largest of the two pieces you just made with your crosscut. This should give you a piece of plywood that measures 21-by-60-inches.

2. Set the table saw fence at 1½-inches. From the left over 60-inch piece of plywood, rip two pieces at this measurement. This will be the edging for your countertop.

3. Apply glue to one of the flat sides of the 60-inch piece of edging, turn it over and place it on one of the long edges of the countertop. Secure it with the box nails.

4. Measure and cut two pieces of the edging 19½-inches long from the remaining edging you cut in Step 2. Apply glue to a flat side to these, place them at either end of the countertop and secure them with the box nails.

5. Sand the 60-inch edge with the sanding block to be certain that the edging and the countertop are flush. Place the piece of plastic laminate 2-by-60-inches along the front edge, face down. Next, apply contact cement to the front edge of the countertop only. Do not apply contact cement to the plastic laminate yet.

6. Apply a second coat of contact cement on the wood edge after the first coat is dry. Now apply contact cement to the backside of the 2-inch plastic laminate.

7. Allow both to dry to a tacky feel. Once they are tacky dry, carefully place the plastic laminate on the front edge of the countertop and tap it lightly down its front with the hammer. This will ensure a good bond.

8. Starting at the top surface right hand corner, place the base of the router against the front edge of the countertop and allow the router bit to cut the laminate the full length of the countertop. Next, start on the bottom side from the left and work to the right to cut off the excess plastic laminate. Be certain not to go too fast as it may chip the laminate. Sand the top edge with the belt sander, turn that countertop over and belt sand the bottom side. It is now ready to apply the surface countertop material.

9. Place the 22-by-60-inch plastic laminate face down on a smooth surface. Do not place it on the wood countertop. Next, apply a good coat of contact cement to the wood surface of the countertop. Let this be dry. Then, apply a second coat on the wood surface of the countertop and a first coat on the backside of the laminate. When the contact cement is tacky dry, place the ¾ by ¾-inch lumber to the wood surface and set the plastic laminate on top of the lumber.

10. Remove the lumber pieces one by one and let the contact cement come together to form a good bond. Route the excess laminate off and file the edges with a file to remove the sharp edges.

Tips & Warnings

• Always wear safety glasses when routing plastic laminate. Wait until the complete countertop is built before cleaning off excess contact cement with a clean cloth and Naphtha. Make sure the bearings in the router bits row free before routing the laminate to avoid burning the edges. A countertop that allows for a sink is built the same way, just cutout the wood for the sink before applying contact cement.

• Do not leave power tools unattended. Do not raise the blade of the table saw any higher than necessary to make the cut. Do not apply the contact cement in and done ventilated area or near an open flame.

Resources

• Resurfacing Countertops
• Welcome to Do It Yourself Granite
• Bathroom Countertops