It's been a year since we installed the maple hardwood countertops.
How are they holding up?
What would I do differently?
Most valuable lessons learned?
How are they holding up?
We couldn't be happier. I'd add photos, but they look just about the same as my last post!
The choice of Behlert's Rock Hard table Top Varnish was excellent! I must admit, I had a few second thoughts about it (cost!) but it is wearing like iron! No stains or any sign of wear.
I do admit, we baby the countertops, wiping up stains (usually) within a few minutes. But the island hosts the cooktop and there have been splatters and splashes of hot oil, liquids, etc.
What would I do differently?
I did most of the layup and glue work in the late summer when humidity was high. In addition, a few of the boards had a very slight bend or warp. As a result, there are 3-4 places where very small gaps opened up on the top where two boards were glued together. I believe this could have been prevented had I been fussier with selecting only the straightest pieces and using more and heavier clamps.
The downside of being more picky is wood scrap - but if you have another use for the stuff, that's not a big deal. Also, if you are not far from the mill, you could return for exchange. All in all, the extra cost would have been worth it.
I had two 3/4" pipe clamps and used them when I needed a lot of "squeeze." I should have sprung for four more of these heavier pipe clamps to really put a heavy squeeze over the whole length.
I selected to use short pieces (5" over all length) for the section to the left of the cooktop. I had originally planned on using a single long piece and I should have. Several small gaps opened up in this section. It is very difficult to clamp very short pieces.
Most valuable lessons learned?
Be picky for straight wood.
Don't get hung up on a relatively small expense (e.g. varnish at $28/qt) if the contribution is a small fraction of overall project expense.
Lay up and glue in low humidity (i.e. winter) if possible.
You can't have too much clamping pressure.
Use 200 grit or higher on your sanders including the belt sander.
Start small - I did a roll around cart top first.
If you build in the basement, make a full size light weight mockup to make sure you can get it it out of the basement!
Above all, if you think you have the skills and space to do something like this - Go for it!
I hope this blog helps someone do a similar project.
If you do, post a comment on my blog.
Good luck and God bless!
