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 Saturday, November 21, 2009
Weekly Project Categories » Tile

Weekly Project



Lessen the Trial of Tile

If the tile counter of your bathroom vanity reminds you of ancient Greece or Rome rather than a bathroom of the '90s, it may be time to replace it.

There is available a variety of tile sizes, colors, patterns and trim pieces. Grout color and thickness are other variables.

In the past, installing ceramic tile most often was left to a tile mason. The advent of pre-fabricated mortar board and the profusion of "how-to" information, like this column, have made tile installation by the homeowner more doable.

Start by removing the existing faucet, sink and tile top. Turn off the angle-stop valves under the sink, and using a pair of channel-lock pliers disconnect the water supplies and P-trap. The tile and existing wood substrate each can be removed with a hammer and a small pry bar. Wear protective eye goggles to avoid injury.

Once the demolition phase is completed, you're ready to begin your new installation by first measuring, cutting and installing the new plywood rough top. Three-quarter-inch exterior grade plywood will be fine. Cut the plywood even with the finished face of the cabinet. Use 1 5/8" bugle-head drywall screws to attach the plywood to the vanity. Pre-drill the faceframe prior to installing the screws to avoid splitting. Next, using a template, mark the location where the sink will be installed and cut out the corresponding hole with a jigsaw. Apply a layer of 15-lb. building paper over the plywood top, securing it with a few staples.

The next step for a professional would be to float out a bed of mortar. For the do-it-yourselfer, the pre-fabricated cement backer board makes the job easier. Measure the backer board to fit precisely over the plywood rough top below. The backer board which is 1/2" thick can be cut with a sharp razor knife or by using a circular saw with a masonry blade. If you opt to use the saw, be sure to wear a breather mask since you will encounter an enormous cloud of dust.

Prior to installing the backer board, lay it on top of the plywood rough top and scribe from below the hole cut in the plywood for the sink. Again, use a jigsaw to cut out a hole in the backer board for the sink. Secure the mortar board to the plywood substrate using 1" galvanized roofing nails or 1" bugle-head drywall screws. Use the special mesh tape and joint compound sold with the backer board to finish the joints. The nail or screw heads should also be dabbed with a bit of the joint compound. Allow the compound to dry overnight.

Start the tiling process by laying out the trim pieces. An outside corner is an easy place to start. Irregular trim pieces should be marked and cut with a tile cutter which can be rented for about $10 a day. Next, lay the field tile out with the appropriate-size rubber spacers and mark and cut each piece as necessary. The rubber spacers help to keep the joints aligned and uniform in width. The most challenging pieces to fit will be those which surround the opening for the sink. In addition to the tile cutter you may find that using a pair of tile nippers will make custom cuts far easier.

Once all of the pieces have been pre-cut to fit, remove them and, using a 1/8" notched trowel, apply the thinset mortar adhesive to the backer board. With a margin trowel or butter trowel spread a small amount of mortar on the back side of each piece. Place the tile, starting with the trim pieces followed by the field tile, being sure to use spacers between each piece. The tile splash can be applied directly to the wall by using a small amount of mortar with each piece. Allow the tile to set about 24 hours and then apply the grout. If the joints are less than 1/8", use unsanded grout. If 1/8" or larger, use sanded. Mix the grout according to the directions and apply it with a rubber grout float working in a diagonal direction. Excess grout should be removed with a damp sponge. Apply an acrylic or silicone-based tile and grout sealer to the entire tile and grout surface after the grout has cured for a couple of weeks.

Finish the job by installing a new self-rimming sink and decorative faucet. Reconnect the water supply lines, install a new P-trap and open the shut-off valves.

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Random Weekly Project!
Ceramic Tile and Cement Mortarboard
When we were carpenter-apprentices we saw many homes being built with tile showers where the tile was glued directly to the wallboard. Before then we had only seen tile installed over a layer of mortar. We were convinced that this new mortarless installation was a rather simple process.


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