Epoxy River Table in 12 Steps
Cut the wood slab to desired size. Remove the bark with a pry bar and hammer. Use a sanding disc on a grinder to clean up any stubborn bark. Cut your slab in half with a circular saw.
Step #2: Build your Casting Epoxy Form.
We used a sheet of Melamine wood for our form on this project. Determine the thickness of your wood slabs and cut the form sides 1/2'' taller of your wood slab. Apply Tyvek tape to the bottom and sides, overlap the tape. Screw down and secure the pieces together. Use Tyvek tape to seal where the sides meets the bottom to keep from leaking.
Step #3: Level the bottom & seal the slabs live edge.
Using the Slab Jig, level the bottom of your slabs. Remove 1/8''-1/4'' per pass until mostly level. Return wood slabs to your form. Mix Stone Coat's Quick Coat and apply to the live edge of the wood slab. Quick Coat is a 1:1 ratio by volume fast curing epoxy. Mix for 2 minutes with a drill and paddle mixer. Apply mixed Quick Coat with a brush or gloved hand.
Step #4: Pour the Casting Epoxy River
Casting Epoxy or Thick Pour Super Cast Epoxy both are measured at a 2:1 ratio by volume. Add desired metallic powder or epoxy dye. Mix for 5-8 minutes by hand using a mixing stick. Pour the Casting Epoxy or Super Cast into the river form, torch the epoxy every 1/4'' to remove air.
Step #5: Remove your river table from form & install support bars.
Use a pry or flat bar to remove table from form when the epoxy river is hard. Router multiple channels in the bottom of the table to install 3/4'' x 3/4'' tube steel to keep your project from cupping in the future. Use Quick Coat to install your support bars. Quick Coat - 1:1 ratio by volume, mix 2 min. Remove excess Quick Coat with a bondo spreader or squeegee.
Step #6: Level the top with the Slab Jig, roundover the edge & sand.
Quickly bring the table top to level using the Slab Jig. Remove 1/8''-1/4'' per pass until level. Use a 1/8'' roundover bit to round the top and bottom edges. Sand the surface and edges with 60-220 grit sandpaper.
Step #7: Seal your table with Stone Coat Countertop Epoxy
Apply 3 seal coats of Stone Coat Countertop Epoxy. A Seal Coat is measured and mixed at 1 oz of mixed epoxy per square foot of table top. Stone Coat Countertop Epoxy is mixed at a 1:1 ratio by volume, mix for 2 minutes with a drill & paddle mixer. Spread the mixed epoxy with a shower squeegee. Use a propane torch to quickly remove air incorporated into the epoxy while mixing. Before applying the next seal coat, lightly sand the table with 220 grit sandpaper. Each seal coat will have less air escaping from the wood and have less bubbles than the previous seal coat.
Step #8: Fill remaining pits & cracks.
Use a furniture repair burn in fill-stick to fill and seal any pits or cracks. Heat the end of the fill stick, apply fill-stick material to pit. Use a flat edge razor blade to remove excess fill-stick material.
Step #9: Flood coat your Epoxy River Table.
Use Stone Coat Countertop Epoxy to apply a heat, scratch, & U.V. resistant flood coat. Flood coats are measured and mixed at 3 ounces of mixed epoxy per square foot of tabletop. Stone Coat Countertop Epoxy is a 1:1 ratio by volume epoxy, mix for 2 minutes with a drill and paddle mixer. Pour mixed epoxy onto the center of the table, use a 1/8'' x 1/8'' square notch trowel to evenly spread the epoxy. Using the heel of a brush, chop the top to remove trowel lines and ensure one last mix. Next remove the air from the epoxy with a propane torch. Torch the surface at least 3 times in a sweeping motion to remove all air.
Step #10: Remove dried drips.
Use a grinder and a 50 grit metal fiber sanding disc or a orbital sander to remove the dried epoxy drips from the bottom of the project.
Step #11: Install on cabinets or install table legs.
Install on cabinets: Ensure your table overhangs the cabinets evenly. Tape off the cabs with delicate release tape. Use 100% silicone to secure your table to the cabinet. Installing table legs: Layout and pre drill where your table legs will be installed. Use lag bolts to secure the legs.
Step #12: Enjoy your Epoxy River Table.
Your table will last many years to come. To clean use any countertop cleaner designed for laminate or solid surface countertops. We like dish soap on a soft cloth. Keep from using a cleaner with any scrubbing additives. Use our Liquid Smooth product for a pleasant finishing touch. The epoxy will be cured to its full scratch and U.V resistance after a 30-day cure. Begin using your new table after a 72-hour cure.