renovating kitchen & I've searched the internet for inexpensive but quality countertop ideas. found information on epoxy grout countertop - the entire countertop is the epoxy grout, no tiles - very little information except to use cement board as the base, thin the epoxy grout and use some sort of non-stick material to create forms. I've contacted a manufacturer of a sanded epoxy grout & asked them about this type usage & was told they felt like it would work but would not give any ideas on how to go about doing it.
So here are my thoughts & questions: I'll use 1/2" plywood & 1/2" cement board - level it out - I'm using painted roof flashing metal as a backsplash & will mount that before pouring out epoxy grout - I'll use some left over FRP (fiberglass reinforced panel) strips & coat them with petroleum jelly to create the form at the front edge of the countertop and around the cut-out for the sink and seal the edge where the FRP meets the plywood/cement board with an acrylic caulk - I'll pour out the epoxy grout & use a regular trowel to level it out - after it has set for 15 minutes or so I'll come back in with a steel trowel to smooth out the top surface.
Questions: I want a white countertop, can epoxy grout be dyed or a surface product be applied that is white? Can epoxy grout be thinned? If so with what? If the surface is not as smooth as I am hoping to get it with just the steel trowel can it be sanded? I'm thinking of going about a 1/2" thick with the epoxy grout - should I go thicker or thinner & how much longer might it take to dry? What can I do about a front edge treatment?
So far I have spent less than $5,000 to purchase new sub-floor & flooring, cabinets, appliances, sink/faucet, paint & so on and am hoping to keep it below $6,000. At some time in the future will look into a different type of countertop if this material won't last as long as I am hoping it will.
Any advice/ideas/help would be appreciated! Thank you so much - Kate in Butte, Montana