Expert: Jamie Yocono - 4/27/2009

Question
Aloha,
i was woundering if i could make a bar top out of just3/4" oak veneer plywood with solid oak wrap around edgeing. it will over hang a 2x4 partition about 19", and is 8 ft  long. We were going to use three heavy duty shelf brackets as knee brace.
i read many things saying it should be 1 3/4" inch thick. Why would it have to be so thick or does it?
Will one sheet of plywood warp?
if i do need to double it , how do i attach it together?
Sorry for so many ? and thank you for any possible A's.
Oh yeah we live in hawaii so not much temp difference though the year.

Answer
Aloha Lara,

A 3/4" sheet of plywood is technically strong enough to be a counter top, but it will sag over the area where it is unsupported and cantilevered. So you do not want to use it just the way it is, you need to beef it up. Also, it's really thin visually; it will give the illusion of a weak and insufficient top.

The best way to create a counter top is to make one with a double layer of the plywood around the edge perimeter. That way the edge of your top will look like the whole thing is 1.5" thick.

The way I make this is to cut 3" strips of the plywood. Then cut the top to it's final size. Around the edge (on the underside of the countertop) lay the 3" strip around the perimeter, applying it with glue and screws. Make sure your edges are flush. And don't use screws that are too long and could pop through the top. When it's time to apply the final solid wood edging to hide the plywood edge, you will use 1x2 edging, which is 1.5 inches wide. It's perfect for covering that double layer of plywood.

Since your countertop is fairly long, you can add some center struts (or brace) underneath, to beef it up. Use that same material for the struts - that 3" strip of plywood. On an eight foot long top, I would add one every two feet. Wherever you plan on adding those corner braces for support, make sure there is a strut so that the angle can attach to the strut under the counter top. It will add strength and support.

Any good kitchen cabinet book will give you diagrams of this construction. I just looked online to send you a link, but couldn't find anything. I suggest looking at this book if it's in your library: Making Kitchen Cabinets by Paul Levine. It's old, but gives excellent info about making countertops. Any kitchen cabinet book should be helpful, though - this is pretty simple countertop construction.

Good luck, write back if you have more questions. This is a simple and straightforward project, you should be able to make this with even very simple tools, as long as you can cut those 3" strips of plywood.

Jamie Yocono
Wood It Is! Custom Cabinetry
Las Vegas, NV
www.wooditis.com