This is by far the biggest project I have done. 2 piece counter top for a shop in Greenwich London turned out to be a challenge and successfully accomplished last night.
The entire design consists of recycled wood and some store bought items. Not everything can be salvaged when it comes to building materials, some stuff you just have to buy. Plywood for walls of the body and for top had to be bought at B&Q along with several items like nails, stains, paints etc.
The carcass is built out of 2×4`s cut in half, one front piece and one funky angled side piece-that last one was not an easy thing to make, to make sure all angles are correct. Then a sheet of plywood was glued and nailed on it to provide a study building block for the wooden mosaic that goes on top of the walls.
My client was interested in keeping the looks of a weathered, old-ish looking wood that you can find in old pallets. The problem with that was the amount of wood-it is not an easy thing to find old looking pallets but with the healthy wood underneath. I had to come up with some way to recreate this look-the artificial way.
Youtube comes to rescue again-it is like a mine of ideas from all over the world-chalkboard paint on rough board and target sanding will bring that effect in no time.
Black chalkboard paint
This is one of the ways to age wood in the grey colours, sort of like an old, time punished pallet. You spray this paint onto ROUGH board-do not sand it before paint application, paint needs to sink into the pores of wood. Then pick up your sander and reveal back some wood from underneath the paint and viola-old, grey looking board ready to work.
There is another way (this time my idea) if you have a hard time getting black chalkboard paint-shoe shine in spray will get you the same looks! Funny but it works though, same procedure, same effect.
Shoe shine black spray
That spray with some black shoe sine in it will do the job just fine-sand it through and you got an old board-from the scratch (kind of a oxymoron here)
After installing the plywood walls I painted them grey-it is usually a good idea to paint the wall for any mosaic in the colours that match the final wall colour. In case your boards have any bows, curves etc. that make the space between the tile visible-that colour from underneath will nicely blend in as oppose leaving it bright brown or while-no one will notice it much-unless the gap is really big-then you go and fix that f-up.
Grey paint under the tiles
Slowly building up.
Contrast of clean, brown plywood and grey paint
Interlocking corner looks nicer
Inside of the counter a shelve made out of recycled wood and treated with teak oil to bring nice colours.
This entire counter top had to be designed in a way that makes it possible to take both parts apart in order to deliver. Both were screw together at the store and no glue was applied-this way it can be dismembered at will and removed or relocated.
The very outward corner was interlocked and screwed from the inside-no need for glue-this made a very tight construction.
This way is nearly impossible to track the exact wood connection- and makes it more interesting that face to face meeting point.
Top was made out of solid, wide pine boards, treated exactly the same way with chalkboard paint and sanding. The only difference was that there was no oil applied on top, just clear coat varnish for protection-thus the natural grey colour remained.
Wide, grey boards on top of plywood
Walls were treated with boiled linseed oil that changed the colours a bit, but brought out the grains and intensified the looks. ( will post some pictures soon)
This project was a lot of work though, every piece of board for outside mosaic was cut, painted, sanded and installed separately. This is the only way to ensure that the wall will look like tiles, otherwise it would blend into one big board and loose the effect. But it`s well worth the effort, looks cool I think.
More pics coming from the shop this time.