[Dani Homrich]

In Michigan we aren’t
building many tops, but the repair business is booming. I just repaired an 11”
crack in a 21 year old Avonite top, old CA material. I was really surprised
when I saw the top because all the cabinets had the Avonite door & drawer Pulls
that I use to make in the late 80’s & early 90’s. I was lucky the customer
had a piece of repair material, or should I say a very small piece ( 4” X 6” ).
With out having very much material to work with I had to do a Dog leg on the
repair. I will add the customer wanted no dust and the kitchen floor was dark Cherry
hard wood.  The first photo is the crack
I had to repair. The crack is a stress crack because the top is about 1/16”
higher over the cracked area.

This is my setup; I put my moving pad on the floor then the
Dow underlayment on top of the pad. Covered the front of the cabinets and cook
top with 36” mastic and a border around the work area with the Dow. I marked
the cut area and setup the straight edge with Nylon glue blocks and located the
stop blocks using the cutter on the router.

There was no dust from the first cut and this is all the
dust from the second cut. I call this dust free. I used a single flute insert
plunge bit to cut the Dog leg.

I used
a Dremel to open up the remaining crack for adhesive. The material left was
1/16” thick. I sanded the radius ends with my foam hand pad first then cut the
angles with a chop saw to get a perfect fit.

Here are the 2 pieces glued and in place. I under sized the
repair pieces by 0.10 mm, just enough for adhesive. The square on the right is
a chip I filled. I use a 500w Halogen to speed up the cure time. Then I wet sanded
the repair with 100mic than 60mic. In a customers house I always slow the speed
down on the sander to reduce the fling of sanding goop. I use a speed setting of
4 on the Porter-Cable.

Here I am blending the old finish with the new using the
Perfect Finish, because it is a very thin film of compound I use the Porter-Cable
on a speed setting of 5 or 6 to speed up the process. If you notice there is very
little splatter on the Dow and this is after the entire sanding procedure.

End part one

[Dani Homrich]

Part two

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Here is the finished job and there is only a little water
that ran down the front of the mastic and ended up on the Dow. For cleanup I
wiped up the water on the floor pulled off the mastic and folded up the Dow
underlayment. I really like the Dow it comes folded in 2’ X 4’ sheets and open
up to 8’, it is water proof, saves the floor from things being dropped, easy to
cut and tape together, and you can use it as a screen by standing it up in a zigzag.
 At this point I had the customer look at
the job and they couldn’t find the repair and said it look much better than
they expected and thanks for keeping our house clean. I was hoping for a beer,
but no such luck.

When I finished I had no dust or mess to clean and I am ready for my next repair.

[John Christensen]

Nice repair.   Excellent dust control.  I keep a roll of 36″ plastic mastic in the truck at all times.  Works great and it is tacky on the back for easy set up.  I might need to get some of that dow underlayment though.

I am skeptical that the 1/16″  pushing up on the middle of the field would have cradked the top alone, without any help from a crock pot or the like.  Try getting a customer to admit to that though.

Johnny C

[Un-Authorized]

Posted By Johnny C on 07 Apr 2009 08:19 PM
Nice repair.   Excellent dust control.  I keep a roll of 36″ plastic mastic in the truck at all times.  Works great and it is tacky on the back for easy set up.  I might need to get some of that dow underlayment though.

I am skeptical that the 1/16″  pushing up on the middle of the field would have cradked the top alone, without any help from a crock pot or the like.  Try getting a customer to admit to that though.

Johnny C

Johnny:

I can’t disagree with a word. It’s a nice repair and excellent dust control.

I’ll bet there’s a duplex recepticle hiding behind that Dow board where the crock pot was plugged in. Kind of like this:

The screwdriver tip  and the mini flashlight point to the arc of the crack, the pen runs parallel to the back of the crack. The texture of the particulate at the pen is raised. How’d the breath of that dishwasher make it all the way back there? I’m waiting for a manufacturer’s decision on this one.

Joe

[Jon Olson]

Nice Work.

[Mike Gladstone]

Looks really good. Excellent dust control.

[Curt Herrmann]

Dani,    What did you do to correct the high spot?  Nice repair!

Curt

[Karl Crooks]

Posted By Dani Homrich on 07 Apr 2009 07:29 PM

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There was no dust from the first cut and this is all the dust from the second cut. I call this dust free. I used a single flute insert plunge bit to cut the Dog leg.

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Great job Dani and nice to see you posting here !!!

Not that it matters much but you can put a peice of tape over the top of the first cut before you go to do your 2nd cut and you will be truly dustless !!!

[Karl Crooks]

Posted By Johnny C on 07 Apr 2009 08:19 PM
Nice repair.   Excellent dust control.  I keep a roll of 36″ plastic mastic in the truck at all times.  Works great and it is tacky on the back for easy set up.  I might need to get some of that dow underlayment though.

I am skeptical that the 1/16″  pushing up on the middle of the field would have cradked the top alone, without any help from a crock pot or the like.  Try getting a customer to admit to that though.

Johnny C

I agree with Johnny some thing got to hot, not that is really matters with 21 year old tops as the customer pays to fix it. 

 

[Karl Crooks]

Posted By Kowboy on 07 Apr 2009 09:56 PM

Posted By Johnny C on 07 Apr 2009 08:19 PM
Nice repair.   Excellent dust control.  I keep a roll of 36″ plastic mastic in the truck at all times.  Works great and it is tacky on the back for easy set up.  I might need to get some of that dow underlayment though.

I am skeptical that the 1/16″  pushing up on the middle of the field would have cradked the top alone, without any help from a crock pot or the like.  Try getting a customer to admit to that though.

Johnny C

Johnny:

I can’t disagree with a word. It’s a nice repair and excellent dust control.

I’ll bet there’s a duplex recepticle hiding behind that Dow board where the crock pot was plugged in. Kind of like this:

The screwdriver tip  and the mini flashlight point to the arc of the crack, the pen runs parallel to the back of the crack. The texture of the particulate at the pen is raised. How’d the breath of that dishwasher make it all the way back there? I’m waiting for a manufacturer’s decision on this one.

Joe

Joe, thats a big one, will you remove the dish washer to reinforce the repair? What color is that top ???

[Dani Homrich]

Posted By Curt H on 08 Apr 2009 08:11 AM

Dani,    What did you do to correct the high spot?  Nice repair!

Curt

Curt

I sanded out the high spot with the 100

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µ and checked with my 24″ adj square. Being the top is 21 yr old there are many ups and downs. The repair took 4 hr from start to recieving my check.

[Linda Graves]

Dani,

Was that the Class III Limestone?

Linda

[Dani Homrich]

Linda

Class III Desert Sand P2200 made in 1988

[Un-Authorized]

Posted By Karl Crooks on 08 Apr 2009 09:40 AM

Johnny:

I can’t disagree with a word. It’s a nice repair and excellent dust control.

I’ll bet there’s a duplex recepticle hiding behind that Dow board where the crock pot was plugged in. Kind of like this:

The screwdriver tip  and the mini flashlight point to the arc of the crack, the pen runs parallel to the back of the crack. The texture of the particulate at the pen is raised. How’d the breath of that dishwasher make it all the way back there? I’m waiting for a manufacturer’s decision on this one.

Joe

Joe, thats a big one, will you remove the dish washer to reinforce the repair? What color is that top ???

Karl:

This is a Corian Platinum knock-off, which should be an easier color/particulate to repair. Since I’ve got such easy access through the dishwasher, I’ll support the repair.

Joe

[Author]

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