Final Picture First

Based off of some plans from DIYpete and Ana-white (gaby kitchen island plans)

Shopping List:

* 4" x 4" - 2 (8')
* 2" x 6" - 1 (8')
* 2" x 4" - 1 (8')
* 3/8" x 5" Lags - 12
* 3/8" Washers - bag
* 2 1/2" Pocket Screws- 24
* 4' x 8' Melamine
* Silicone caulk (black)
* ProFinish 5000 concrete - 2 bags
* 4' x 8' Styrofoam Insulation
* Acrylic concrete sealer
* Trowel
* Mixing tub
* Nitrile Gloves
* 1-5/8" Drywall Screws
* Plastic Drop Cloth

Cut List:

* 4- 28"-- 4" x 4"
* 2- 22"-- 4" x 4"
* 1- 47"-- 2" x 4"
* 1- 47"-- 2" x 6"
* 2- 15"-- 2" x 6"
* 1- 60" x 30"--Melamine
* 2- 64" x 2 1/4" --Melamine
* 2- 34" x 2 1/4"--Melamine

This was just for one, I went back to get more wood and concrete for the second one.

Cutting and notching supports. I definitely should have paid more attention to grain/wood color when I bought these. I wasn't exactly sure how I would finish though, I guess that is something to consider first.

The plans called for pocket screws, but those don't really hold up well. I still used them, but it was because I didn't have enough clamps. I drove the 3/8" Lags through to hold everything tight with the concrete.

Here is where things went awry. I tried drawers at first...Trying to fit 3 drawers perfectly was proving beyond my capabilities and patience. They had to be pretty shallow to fit myself seated underneath and it was a pain. Broke one trying to fit it in and said forget it. Drawers are stupid.

I was using lag bolts sparingly, because I didn't want to go back to the store. I put a tung oil finish on and voila here is my table base. I'm pretty happy with it, just don't pull out the level.

Cutting the Melamine and building the form. No steps of this because it was hard enough to manuever this big sheet around alone in my garage. Attached with 1-5/8" drywall screws.

Caulked and level. I also put some tape over the exposed edges...just because.

After this pic I ended up taking all of it out and trying it again. 1-1/2" thick total slab, with 1/2" foam core. Concrete was too dry and didn't level out exactly. It's really hard to get 1/2" consistency on the bottom of the mold. For the core I just drilled some 3" Diameter holes along it to tie the two halves together and left an inch border. Essentially it creates a box channel with pillars. Should be strong enough for a desk...Also it took EXACTLY 2- 80lb bags, meaning I had nothing left...buy a 3rd bag to have on hand just in case.

You can already see the ghosting. 1/2" thickness probably isn't enough concrete, but I wanted it lighter with the thicker appearance.

I covered and cured it for 7 days, mainly because I had no one to help me get it out of the mold otherwise it might have been 5 days. Popped it out of the mold. Lots of bug holes as the concrete was definitely too dry, but it looks better than I anticipated. Around 160lbs.

Sanded and stained with some acrylic sealer from HD. Yes there is probably better stuff, but I needed this done for work so I just bought it and rolled with it. I tried to fill all the bug holes and after an hour or so I gave up. Some of them worked, but I was trying to use some Quikrete patch mix, that wasn't making it as easy as I thought it would be.

I used the same mold, and tried it again. Using a wetter mix and troweling and vibrating (slamming the table) before I put the foam core in. A lot less ghosting, and almost no bug holes. Since my mold was still good, you only end up using a bit of the sealer, and I had enough foam left to piece together one more core, it was much more cost effective to make 2 rather than just one.

Final with 2 desks. One is standing height for when I want to work standing. Still have plans for some cord management.