I made a concrete countertop for my egg table.

cortguitarman

I used silicone. No plywood or anything. Just 2x4 supports. The top is heavy, but she'll slide on you if you lean on it without silicone.

RandallB

ChockOnSmoke....what is the foam cutout material exactly????  It Looks perfect.  

I did a concrete countertop last summer.  It's about 3.5' by 7' feet by 2 inches thick. I did it in two pieces because of weight.  I put rebar around the "egg hole" side and no structural support on the other side. I used Quikrete countertop mix.  No cracks anywhere after a year.

ChokeOnSmoke

ChokeOnSmoke....what is the foam cutout material exactly???? It Looks perfect.

Foam wall insulation (that you can find at any home improvement store).  It usually comes in 4'x8' sheets in various widths. I cut it roughly with a utility knife and then hand sanded it a bit to make it smooth.

ChefBubba

In the foam board 'knockout' what do you line the edge of the foam board with?

 

Also, what is the best way to 'finish' the top surface if you do not have a wet grinder?  Does it come out smooth enough to do some light hand sanding and sealing and be OK?

nolaegghead

I've been tempted to buy this kit: http://www.amazon.com/Hardin-HWVPOLSET-Variable-Polisher-Polishing/dp/B003EIS674/ref=sr_1_2?ie=UTF8&qid=1342621850&sr=8-2&keywords=stone+polishing+kit

OMG Eggs

I've been tempted to buy this kit: http://www.amazon.com/Hardin-HWVPOLSET-Variable-Polisher-Polishing/dp/B003EIS674/ref=sr_1_2?ie=UTF8&qid=1342621850&sr=8-2&keywords=stone+polishing+kit

If you wanted to save a few bucks, you just crab the pads and get a cheap grinder from Harbor Freight for $20 or $30.

nolaegghead

Yeah, those Harbor Freight grinders have plastic gears, buddy of mine said his wore out after a few hours of use.  I have a good Hitachi and Milwaukee grinder, but they don't have the water sprayer and shield.

RandallB

Version 2 of the top is getting ready to go.  Hopefully improving on what I learned.  I may have time to pour it tonight.

I also made a custom 15x15x2.75'' pad for under the egg, to maybe have a matching set top and bottom on color.

nolaegghead

That mix looks a little wet - shouldn't you mix it up as dry as possible to minimize shrinking (and cracking)?  Other than that, looks good!  That melamine is the way to go.

RandallB

It may be a little wet.  When you vibrate it hard with the small hand sander, the water seems to come up.  That is the runoff on the sides.    I took the 15x15 piece out last night (3.5 day dry) and it is REALLY nice.   There are like 3 bubble marks in the whole thing.  Edges and corners are perfect.  I think my improved technique on the caulk is good.   I applied very small amout of caulk with my finger and took my time, then wiped off excess quickly with acetone, leaving only the tiny corner crack filled.   Also used brown color silicon caulk so you can see it very well against the stark white melamine. 

RandallB

My base turned out perfect. Great edges and corners and no sign of caulk lines.    I am really happy with it.  I will unmold my table top on Sunday afternoon.

Now I am shopping for acid stain.

RandallB

Not the best picture, but here is the top and bottom pieces out of the mold.  I am very happy with them overall.  I improved a lot from the first try.

Next, I am reading on how to properly fill the few bubble holes and select an acid stain.

 

Rubmyrock

@chokeonsmoke, love your design but what's with the little cut out in the back and why not enclose the front?

nolaegghead

Looks really nice!

ChokeOnSmoke

@chokeonsmoke, love your design but what's with the little cut out in the back and why not enclose the front?

The cut out in the back is so the hinges can drop down below the level of the tabletop.  I wanted to reduce how much the egg stuck out the top of the table.  Thought it looked better that way.

Yeah, I didn't want to enclose it when I built it because I had just started doing competitions and it was 10 times easier to move it that way than to remove it and/or put it back in through the top.

ChokeOnSmoke

Now I am shopping for acid stain.

You'll have to let me know what you come up with.  I looked into acid stain when I first did mine but I never followed through with it.  All I did was sand the sharp edge a little and put a clear coat on it.