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Dchambers25

Impending bbq island build

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Hi all. I posted this in TFP forums also but decided to post here also to get more feedback. Riles already gave me a few helpful tips over there and I am hoping I can get a few more. After reading through all of the posts here I have decided to get my feet wet (and maybe my back sore) and build my own bbq island. I hope to start early next month after the patio cover is installed. I think I have a game plan now and hopefully it doesn't blow up in my face.

 

 

It goes like this:

Have patio cover installed.

Run electrical to panel.

Frame grill island

Run rough electrical in island.

Sheet island with cement back

build forms and pour concrete.

Rock the sides of island.

Do finish electrical

Seal Counter.

Drink beer and fire up grill

 

My materials/component list so far:

40" Blaze grill- propane

40" Blaze double access door

21" Blaze access drawer

18" OCI tilt out trash bin

16" double drawer150 sq. ft of Coronado dry stack veneer stone

Blaze side burner

4.6 cu ft Blaze fridge

 

All components are 304 stainless.

 

 

I know a lot of people use hardibacker, but I want something that is rated for exterior use, and thru my research the only two backers and PermaBase and WonderBoard. I am a contractor (not a general or else this would be easy), so I have worked extensively with all the cement boards thru the years and kinda like Wonderboard the best. I am going back and forth on whether or not to put a scratch coat on the cement backer, or just to apply a waterproof membrane like red guard. The manufacturer said lath and paper are not required for this type of substrate, but does recommend a bond coat. Gonna use 20 gauge g60 studs, figure it couldn't hurt with the rigidity of the island with the concrete counters. Trex ft on bottom. I am going to pour the u-shaped concrete counter in place to eliminate seams, but my plan is to put the two raised bar slabs in detached forms because I really want to add fiber optics in them. Don't know if I will figure out how to do that, but hey, everyone has to have goals right?

 

I will attach a few pics of what I have drawn up so far.

 

 

Yard as it stands now

 

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backyardlayout.PDF

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Can I ask what made you go w/ the 40 inch grill vs. 32. I am currently debating the size question. I usually know bigger is always better but I am worried about overall counter space - and wondering if I'll ever really use enough of the 40.

If I use the 40 I will only have 24 inches on 1 side and 12 on the other....

If I use the 32 I'll have 28 and 16 as counter space either side...

 

Any opinions or thoughts on size?

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Finally started with the framing. The patio cover was just completed and I ran electrical to the ceiling fan location, and put an outlet on the beam on the cover today. Running wire inside it was a pain, and getting wire to the outlet was a pain but its done now. Wish I would have had the patio company run it when they put it up.

 

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Started the basic layout. Squared everything up

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Then added 1/2 perma to the bottom. Ran out of trex, as I will have three access areas here I am reinforcing with trek. Cutting the metal studs isn't bad. First time working with them so we will see how it goes

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Got another half day of work in over the weekend. This project is going to take longer than I thought. I take breaks and make sure baby duty isn't getting the better of my wife.

 

The first thing I did was silicone pest netting around the patio over posts where the permabase left gaps. I figure the netting aids in air circulation inside the structure, as well as keeping any unwanted pest from entering in.

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Next I unpacked all of my opponents to verify the cutout measurements. Then I started stick framing the structure. I had three levels going and wish I had one more. Hopefully this weekend I can finish up the framing and do the electrical rough.

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another half a day of work in today before I ran out of studs. I probably have as many hours in the raised bar than I have in the rest of the project. I used simpson L straps attached with bolts, to studs 12" OC. I wanted to make sure it could handle the concrete counter.

 

 

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I have all of the cutouts done and the studs attached. I am going to add a few shadow boxes on the end so I still have to frame those out.

 

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I was concerned about the doors being recessed since I am going with a veneer stone, and the stone is about 1 1/2" thick. Add the mortar and that makes a 2 inch projection from the substrate. So I cut the side of the stud, hammered them flat, to give me another 2 1/2 inch fur out at each opening. I realize the integrity of the stud was compromised with this procedure, so I added another stud on each side of the opening. This is the point where I am glad that I decided to go with the 20 gauge instead of the 25, because I don't think this method would have been as forgiving with a 25 gauge stud. And since I purchased the 20 gauge studs and track from a building supply, they were actually cheaper than the 25 gauge metal Home Depot carried. The only downside I could possibly see to using 20 gauge is the increased difficulty in cutting the metal. I have a porta band saw but have not used it because it is much faster to cut the metal by hand. This is a pic of the modified stud for the cutout opening

 

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So CA has had its worst drought in years and of course it starts raining when I begin my build. its been raining intermittently for a few weeks now. We need the rain, and it forces me to take my time with the build so I guess its a really good thing.

 

I worked on the rough electrical for a few hours last weekend, and got in enough time today to make the connections and test them all. Hung the ceiling fan on the patio cover but was disappointed that the universal remote transmitter didn't fit into the bracket housing. I don't think there is a remedy for that. I kinda wish now I would have gotten a ceiling fan that already came with the remote, that way there would be no need for a transmitter, but my wife really liked the ceiling fan and she doesn't mind going outside and pulling the chain to turn it on. I also dry fit all the drawers and doors. Things have been going pretty smoothly. I hope to have all the cement board up this weekend and then start on the forms for the countertop. Its looking good so far and I can't wait til everything is done

 

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I was able to get 10 hours of work in over the weekend.

 

Started with finishing the run of low voltage cable,. Then I cut and caulked in foam board around the fridge area for insulation. I kept the board up high where the motor is located in the back of the fridge, and cut out vents in the cement board to vent out to the exterior Hopefully this will allow the motor to kick out heat to the outside of the island, as well as insulate it from the ambient heat generated from inside of the island. A sheet of polystyrene foam board was only $10, hopeltfuly I will see the savings on my monthly electric bill.

 

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I have just about all of the cement board cut and attached. I just have to screw down the top and tape and mud the seams. Then on to the concrete forms. Hopefully, I can get the concrete poured next weekend.

 

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I was building forms all weekend…

 

 

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To be fair, I do have 75 sq ft countertop tops, 2 backslashes, and I am also pouring concrete to fit inside the two shadowboxes. So its a lot of cutting and measuring the melamine. I got the reinforcement elevated in the lower one third of the countertop Just used the cement board screws to bite into the cement board, the used rebar ties to attach then wire to the screws. It isn't going anywhere, and I wanted to be sure of that while i was pouring the concrete.

 

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15 80# bags of Quikrete countertop top mix. Now comes the hard part… unloading 1200 pounds of concrete.

 

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I got started today. I poured all the pour in place counters. It was about 70 sq ft. Took me all day working alone. Wasn't too hard, but just a lot of steps involved. It would help to have another set of hands. the only thing worse than unloading the 80 pound bags are lifting them up into the mixer. I ran out of concrete so i am gonna get some more. I might just use the quikrete 5000 for the backslashes and the shadowboxes.

 

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Coming along nicely...lots of work. Are you cutting the studs with the grinder? I'm using snips, and is feeling it!

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1395161489[/url]' post='93286']

Coming along nicely...lots of work. Are you cutting the studs with the grinder? I'm using snips, and is feeling it!

 

 

 

Thanx. I am just using metal snips. I used the grinder to shave down a few studs, mostly studs that I had already attached to the frame.

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Got started grinding today

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The process isn't that hard, just a little time consuming. I got in about 6 hours of grinding. Started with the 50 pad then went to the 100, then put on a slurry coat. I am not sure if I will be able to get any more grinding in this weekend. The only part I wish I would have done differently is made the concrete mix more soupy from the start. The bar area has some big voids in it next to where the forms were. Nothing a little slurry couldn't fix, but it just would have saved some time

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Still plugging away. I figure I got about another week or so before everything is pretty much buttoned up.

Here is a shot before I put on the concrete countertop sealer9b5263263846a74ac6662777a3b31e10.jpg

 

 

 

 

 

Now here the patio is sealed, as well as the countertop. I am really happy with the sealer. It's called Surecrete xs-pc12. Easy to apply and brings out an incredible shined86e5e91c4e4874640e1b38265129a57.jpg

 

 

All I have left is just the stone and the backsplashes and shadow boxes which will be decorative tile. I also want to trim the post out, just waiting for the trim to come in. I want it to look like the posts are sitting on the countertop.

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Wow, does look good...that thing is waterproof!!! :) Putting lights in the shadow boxes? Any lights in the counter top overhang?

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1396960065[/url]' post='93362']

Wow, does look good...that thing is waterproof!!! :) Putting lights in the shadow boxes? Any lights in the counter top overhang?

 

Thanx!

Yes I have lights all over. I have a string of led lights that I cut and put under the bar on the countertop side and under the raised bar to the left, then I cut the remaining lights to have access lighting in both shadowboxes, as well as a light under the counter overhang at each door, drawer, and fridge opening. I added accent lighting around the perimeter of the bbq spaced every three feet or so, and also added the LEDs in the propane storage compartment, and under the grill in the double access doors. I wired up an led controller that dims the brightness. They look cool at night. It was alot of soldering and heat shrink, but was fairly inexpensive. I looked at a set of lights from HD that was gonna run about $60 for four, but all of my lights, wiring, dimmer, solder and heat shrink I got off amazon for around $30, which was a pretty good deal considering I have lights in almost 20 places.

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I was able to get a days work in over the weekend. I had hoped to get three days of work in since I had Friday off, but it just didn't happen. I started off by setting all the decorative tile in the shadow boxes. I originally planned to trim them out with concrete, but the slabs didn't look right to me hen I set them in the boxes. So tile it is then. I also set the glass tile on the backsplashes. Then my brother came over and helped me drop in the grill. I had to use the grinder with a diamond wheel to trim off just a little of the concrete on each side at the front of the counter so the grill would slide all the way back. Now it fits like a glove. My brother also helped me set the raised bar concrete slab on the left. Set all the components in then worked about an hour on the stone.

 

Shadowbox on the right leg of the island. I furred out the opening with permabase, then picture framed the opening. My wife picked out the tile for the back of the box.

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Grill in. Raised bar countertop set on left side. Doors, fridge, and drawer frame screwed in. Backsplash tile is set. Needs to be grouted.

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Stone started. I did just a little and then stopped. I want to see what kind of bond I get to the redguard.

 

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Finally finished up my island. Or should I say I am 99% done. I have to paint the trim around the post and clean up here and there. I started about two and a half months ago. Took two weeks longer than I expected. Not bad.

 

 

 

 

Stone complete. I protected it with a wet look stone sealer. Really brought out the colors.

 

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Shadowbox on the left leg of the island. It's more of a storage for easily accessible items like tiki torches

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Shadowbox on right side of island.

 

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Since I couldn't find any baseboard that was weatherproof, I had to make my own from pvc stock. This base is consisted of three separate pieces. Still needs to be painted.

 

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Night pics. I didn't have the post column base on in These pics.

 

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Backside of island clearance lightse89808eb1c8768a619736647f860eec0.jpg

 

Propane storage with internal lights, just in case I had to change the tank at night

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Storage under grill unit. Also nice and bright in there with the lights

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I counted and I have about 24 lights around and in the island. Lot of soldering and heat shrink. Some of the soldering performed upside down. Only burned myself 4 times.

 

Now it's time to grill!

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dchambers! That turned out great! Great work.

 

I'm gonna have a a few questions for ya when I start my build.

 

 

Night pics. I didn't have the post column base on in These pics.

 

c761941f7b202e51dbaff41f0b152bf5.jpg

285651588859d66311194188594d780e.jpg

bdaed00ed3142fa35f5d41df70039881.jpg

 

 

 

 

Backside of island clearance lightse89808eb1c8768a619736647f860eec0.jpg

 

Propane storage with internal lights, just in case I had to change the tank at night

5a8a3c42cffa936b41fd61f8f1d8a699.jpg

 

Storage under grill unit. Also nice and bright in there with the lights

2673e7679a9c6531d613d33e27fd8980.jpg

 

I counted and I have about 24 lights around and in the island. Lot of soldering and heat shrink. Some of the soldering performed upside down. Only burned myself 4 times.

 

Now it's time to grill!

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