kitchen butcher block install tips

Time: 20 hours over two days.

Difficulty Rating: This project rates a 4 on the Weekend  


Materials:Sink
Butcher-block counter
Tile

In this week's episode of Weekend Handyman, host Paul Ryan shows you how to give your kitchen a whole new look. The homeowners of this kitchen hadn't made an upgrade in 20 years, and this is the "before" shot, and this is what it looks like "after" Ryan and his helper completed the job! Figure A Figure B Figure C Figure D Figure E After 15 hours of the 20-hour job, it's time to install the countertop in the next segment.

Tools:

Heavy-duty router with straight bit and round over bit
Reciprocating saw with bimetal blade
Circular saw
Impact driver
Tube cutter
Basin wrench
Grinder

Day Two

1. You may need to cut the counter. If so, make careful measurements.

   Tip: A lot of times the temptation is to try to measure the entire length with a tape, and inevitably you end up with a bend in the corner and it is hard to get an accurate measurement. Instead, measure to the middle of the wall (figure A) and make a mark at any number that ends in zero and then measure from the other end to the same mark. Find the number and add the two dimensions together to get the exact length.

    

2. Rig up a straightedge and block off the walls for dust. Cut the butcher block to length with a circular saw and a 60-tooth carbide tip (figure B).

   Tip: Have a helper hold the cut off piece called the "drop."

    

3. Take the measurements from the center of the sink and transfer it to the counter. You need a 5/8 reveal around the sink.

    

4. You need two lines (figure C), one for the rough cut with a circular saw and the outside line is for the finished cut with router.

    

5. Make side cuts -- use the clamps as a stop.

    

6. Practice on a piece of scrap wood and then make the plunge with a circular saw.

    

7. Cut the back.

    

8. To finish rough cutting, use a jigsaw to make clean cuts into each corner.

    

9. Use a router (figure D) for the finished cut with a 1/2" on three passes.

   Expert Tip: When routing, move the router in the same direction as it spins.

    

10. After the straight cut, go back around the opening with a round-over bit for a smooth finish.

     

11. Smooth the edges with some fine sandpaper.

     

12. Seal the open edges with heavy-duty urethane.

     

13. Transfer the holes from the sink to the counter.

     

14. Drill four holes in the counter for the faucet and sprayer with a forstner bit (figure E).

    Expert Tip: The forstner bit is stronger and more accurate than a spade bit and easier to use than a hole saw because it removes all the wood in the hole. Hole saws can also get stuck in this really hard wood.