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Profiling the Edge of a (Man-Made) Granite Countertop - Toolocity Makes It Easy!

January 30, 2012 - After a restless night of sleep, we arrived back at the building early on Saturday to survey the damage in the light of day. Blackmon Mooring worked until midnight, and their crew of 20-25 workers did an excellent job of removing much of the wet and damaged insulation. But much like an iceberg, the actual damage turned out to be much greater then what we first surveyed that morning. The fireman had used a great deal of water and foam in the attic, and we determined that all the Sheetrock on the walls and ceiling along with the insulation would have to come out. This was a big job.

Since we could not work in the building, we decided to turn our attention to the outside work we had planned to do the week of January 30th. Earlier in the month I check with some local contractors on the cost to join the three pieces of the summer kitchen counter top together, and put an edge (called a profile) on it. The cost was outside our budget, and because we are at the end of the project and funds are really low, we had to find an alternative.  I turned to Youtube and found a very helpful video from Toolocity.com -  that shows the step-by-step procedure.  This looked like something we could tackle, so I called the company and asked for their advice. We talked with Marshall Pan who helped us determine exactly what we needed for our job.

Our order included the following:  A Bosch variable speed grinder, a 3/8" radius diamond hand profiler; a set of dry/wet diamond polishing pads (7 pieces from 50 grit to 3000 grit, a liter of Tenax transparent knife-grade polyester with hardener, instructional DVD and a workshop apron.

We ordered and received the package from Toolocity.com in three days.  They have a complete line of diamond tools for granite counter top fabrication, marble and concrete floor restoration. They also offer high quality tools for polishing and grinding.

The counter top is FuzeGlass - a man-made material that is really amazing. It looks natural and the imbedded glass really bring the surface to life.  It is hard to believe it is made from low carbon cement and recycled glass.The FuzeGlass was provided by Brian Egan the President of Southwest Building Products. Here is the step-by-step installation process we followed to bond, profile and polish the FuzeGlass counter top.

      1) After the order arrived we checked to make sure we had everything for the job. We watched the video, and made sure we had safety glasses, and dust mask.
      2) Using a moist rag, we cleaned the counter top to remove any surface dirt.
      3) Our counter top is “L” shaped, and the stone is in three pieces. So the first step was to join the pieces together. It is important to work quickly with the 2 part Tenex cement.
      4) With the all the pieces joined together, we turned out attention to putting a bullnose profile  around the counter top.
      5) Using the electric variable speed grinder and diamond edge router bit, we made multiple passes on the top and bottom edge of the FuzeGlass
      6) When we got the edge looking good we turned our attention to polishing it. We started with the a course pad, and worked our way through to the finest grit pad.
      7) We then polished the surface of the FuzeGlass with the fine pad, then cleaned, sealed and polished it with a kit we bought at Home Depot. 

The job turned out great and there is a great deal of satisfaction in sitting at the bar and enjoying our new countertop. Thanks again to Toolocity and Southwest Building Production for all the help!





Posted by on January 30, 2012

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Overhead view of the FuzeGlass synthetic Granite counter top being profiled.

The first step in the process was to bond the panels together.

The Tenax two part epoxy is mixed together and applied to both edges and top of the Fuze-Glass.

Here is what the edge looked like when the slabs were delivered from Southwest Building Products.

Using the diamond bit, Cliff makes the first pass around the edge of the countertop.

With each successive pass, he takes off more of the edge.

The idea is to work slow and let the tool do the job.

It is important to use a variable speed grinder for the profile work.

Bottom edge of the counter top being routed.

Here is what the edge looks like after it is profiled, but before it is polished.

7 pads are used for polishing the edge and counter top.

Close-up showing the polishing wheel.

This heavy duty shop apron has Velcro strips on both sides that keep the pads handy.

The first few passes with the polishing pads take some time. The smaller grit pads go faster.

Counter top on the short wall wing.

Finished edge after it has been profiled and polished.