As far as clients go, these were the model of ideal. They were laid back, with unique concepts, and open to ideas. We had several in person meetings the first of which was getting the initial concepts of what they wanted, where we discussed the pro's and con's of on-site casting vs. off-site casting.
This was not your common concrete counter top pour. The length alone was just under 12' with a 22" overhang on one side. When you factor in this being a 2.5" thick counter top you can see how, from an engineering standpoint, this becomes a bit tricky (estimated counter top weight: over 1100 lbs). As it will unfold you will see just how important Dave's engineering and steel working backgrounds become.
 |
| Original sketch given to us by the client @ the first meeting. |
So we set off to run some numbers, and make a sample.
The Second Meeting
This meeting was much more brief but involved discussions of cost, counter top color and finish, as well as having the entire counter top banded in steel. Oh yeah, and a decision to go with a modification to the original plan: reclaiming an old round oak dining table and turning it into a lazy Susan that cantilevers over the side of the counter top. The new model would go something like this:
 |
| Conceptual drawing from client incorporating a recycled table. David then suggested making it a Lazy Susan and having no visible support. |
We then set off to make some color samples based on what the client had requested, and planned to make the trip out to their lake house to take measurements.
The Third Meeting
We finally make our first trip down to the lake house, concrete samples in hand. The client spends some time comparing colors and we all discuss options for the existing counter. They debate on keeping the existing counter or having us build a brand new one. We sketch up some rough draft concepts for new counter designs (1) while chatting with them about what they want and what would work with the counter top we will be installing. We also discuss concepts for building a steel frame structure that would carry the load (2). Conversations went from the pros and cons of building the frame inside the existing cabinet to building an exoskeleton, if they decided to keep their current cabinets.
 |
| 1. On-site sketch while discussing concepts for new counter tops we could make them. |
 |
| 2. Concepts for structural support. |
Homework
After having settled on a concrete color and finish we were off to come up with designs for the steel structure. Here are few designs I came up with:
 |
| Different exoskeleton concepts. |
 |
| Another exoskeleton design with options for drawer knobs and pulls we could make. |
Getting Started
This can be best summed up with a series of photos, but I will say that the decision to stick with the old cabinets (circa 1980) ended up taking up so much time to work around that we could have built a brand new set of cabinets for around the same amount of money, and certainly saved a lot of frustration on our part. Unfortunately we don't always have final say, but as long as the client is happy all is good!
Before:
In Progress:
 |
| The cabinet laid on its back exposing the slab. |
 |
| The steel frame in progress. |
 |
| Dave standing on the edges of the frame. He likes to test nearly everything by jumping on it to make sure its strong enough. |
 |
| Another view of the frame in progress |
 |
| The basics of the frame are nearly completed here with the steel banding in place. |
 |
| Ready To Pour! |
 |
| After the counter top had been poured, cured, and sealed. |
The Lazy Susan
It wasn't until nearly the end that a design was chosen for the Lazy Susan. After emailing some concepts they ended up choosing this design:
 |
| Email we sent as a concept. |
 |
| Clear Coated and Ready to Install. Poor Lighting offered at no extra charge. ;) |
Finally It All Comes Together!
While I still haven't seen the island yet with it's new cabinet facings (the client decided to have them refaced near the end), I can only imagine how great it looks. As soon as I get pictures I will certainly add them. Until then, I leave you with these pictures (and video) of the completed project:
 |
| Yikes, thats dusty. |
 |
| Still dusty. |
The client spinning the Lazy Susan:
and finally: Photo Gush:
I had to feature those awesome bar stools the client purchased to go with his new counter top (or who knows, maybe he got the counter top to go with the bar stools, lol).
 |
| $295 |
These can be purchased by following this link.
No comments:
Post a Comment