The FeDibblety family

Old kitchen

One of the major projects on our new house was to put in new kitchen cabinets. We knew before buying the house that many of the lower kitchen cabinets (base cabinets) were damaged. Initially we thought we would try to buy some replacement parts, but as we realized that every base cabinet was damaged in some way, we simply decided to replace them. Ellen did some internet research and discovered that the maker of our cabinets, Mills Pride, was no longer in business. She found some cabinets from Sunco which she thought would match very well. We ended up buying them from Good Value Center. We were quite happy with the service in general. It only took a couple weeks to get them, and they were packed quite well.

This cabinet was completely missing the drawer

The cabinets arrived on Friday the 9th of January. On the 11th, Clare and I spent several hours at Lowe’s putting together a delivery order for all the tile materials we would need like plywood and cementboard. We also got new energy-efficient windows, which will we install once it gets a bit warmer. The materials were delivered on the 12th, and I got to work.

Damaged cabinet

I decided to work on assembling the cabinets while I was waiting for the delivery from Lowe’s. It took me about 2 hours to assemble the first one, but after that it got much easier. The Sunco cabinets have 1/2″ plywood sides and backs, and 3/4″ solid oak faces. They are put together with a cam locking system. I was quite impressed how accurate most of the cuts were. The sides fit into the front and back with a groove, and then get locked into a place with a cam system, which only requires turning one screw about one rotation. The drawers had to be assembled with regular screws, but the holes were all pre-drilled, and were quite accurate. For the first cabinet I screwed the screws in by hand, but for the other ones I used my beloved Black and Decker 18 volt cordless drill, which sped things up quite a bit. I was intrigued by the subtle variations between cabinets. While they were mostly the same, some of the details were slightly different, like the color of the screws, or the type of cushion on the drawers and doors. Some had a soft plastic cushion (the little piece that keeps the drawers and doors from banging shut), while others had more of a squishy foam-like cushion. There is also a fair amount of color variation. Some of the cabinets match the wall cabinets very well, while others don’t match as well.
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cement board taped and mudded

We haven’t posted anything in a couple weeks not for lack of home improvement projects, but rather because we have been spending most of our free time doing them. In the last couple weeks we really started getting serious about finishing the tile around the bathtub.

cement board on wet wall

In the last entry, I estimated that it would only take a few more hours to finish hanging the cementboard. Well, that was an underestimate. It took most of a day, largely because of some minor setbacks, such as having to redo the cut-outs for the pipes in the supporting 2x4s. I had them all done, then when trying to toeshoe one of them in, I simply could not get the nail in, and finally decided to pull it out and screw in the board. However, the board broke while I was trying to get the nail out. Argh! But, I eventually got all the cementboard hung. The next step was to mud and tape the cementboard, which involves putting thinset mortar on the joints, then embedding fiberglass tape made especially for cementboard. This was quite tricky, as the mortar kept falling off my putty knife. I also made the mistake of not doing it all in one step (dinner intervened). I ended up letting half of it dry, then doing the rest another night. Using this method I ended up going over some joints twice (because of the inside corners), which caused some humps. I also put a bit too much mortar on I think, but hopefully the tile won’t fall off the wall.

working out the tile patterns

This past weekend, we finally got to put the tile on the wall. Clare and I spent most of the day Saturday chalking lines on the cementboard, measuring, and cutting tile. Our neighbors, the Greenwell’s, lent us their tile cutter, which was very nice of them. It basically is just a cutting wheel on some rods. You score the tile with the cutting wheel, then snap the tile. Clare started off cutting triagular pieces from the 4″x4″ tile for the fancy pattern we did. Then I started making some of the cuts with the 6″x5″ tile we had measured. I was initially very worried, because the first 2 tiles I attempted broke in the wrong place. Then Clare passed on the advice from her mother to snap the big tiles near the edge of the tile, which worked very well. Besides the tile cutter, we also had tile nippers and a rod saw in our arsenal. The tile nippers are a bit like pliers with a sharp edge, and are good for cutting off rounded pieces. But, after learning the hard way, they do not work very well for inside cuts. That is, if you want to leave all the corners intact, but cut out part of the middle of the tile, the only options are the rod saw or a router (and we did not buy a router just for this project). They make rod saws that fit into hacksaw frames, but we could only find a small one that came in its own frame. It is a small rod which is very rough, almost like sandpaper, but metal and rougher. It works pretty well, but requires a lot of effort. More on that later.

Clare setting tile

On Sunday, we finally got to putting up the tile. I would say that this was probably the easiest part of the job so far. We bought pre-mixed mastic to stick the tiles to the wall. You spread the mastic on with a triangular notched trowel, then simply stick the tiles in. The mastic is very sticky, so the tiles stick almost immediately. The tiles we bought had lugs on them, which are basically little pieces on the side that space the tiles automatically. There were some pieces that we had cut where we needed to use 1/16″ plastic spacers instead. We started with the longest wall of the tub, ensuring that the inside corners would not be as visible as if we had done it the other way around. I got several feet up the wall done while Clare had her weekly chat with her parents. Then she finished off the rest of the wall, and I worked on making a few more cuts we hadn’t gotten to the day before. The trickiest cut by far was the cut for the spout, because it consisted of a circle in the middle of a tile. For this I had to use the special drill bit that came with the rod saw. It probably took me about 10 minutes to drill through the tile, and then another 15 minutes to saw out the hole.

the tricky cut for the tub spout

We continued working on the tile after a little lunch break. After finishing the back wall, I started getting worried about running out of tile. Sure enough, after counting out how many tiles we needed, we realized that we were about 5 tiles short of being able to finish. This was due to 3 factors:

1. We ended up tiling all the way up the wall, which was not our original plan
2. We decided to only do the fancy pattern on the long wall, which was not our original plan
3. We probably ended up breaking more tiles than we had originally thought

So, Clare being the trooper that she is, drove all the way to Bloomington to get about 10 more tiles so we could finish that day. I stayed home and did a few more cuts, cleaned up some, and started laying more tile.

interesting cuts by the ceiling

Another tricky cut was around the shower handle, which was a 4″x4″ hole spanning the middle of two tiles. I thought I had both done, but when I went to put them on the wall, I realized that I had accidentally cut the two tiles upside down, so I had to do them over again. I wanted to continue tiling before the mastic dried out, so I asked Clare to do the last one. Clare, being the ingenius one, decided to use a combination of the rod saw and tile clippers (which I advised against). Sure enough, the tile broke. I was of course a bit upset, and decided to do it myself. I got about 90% done with the cut using the rod saw, and then for some crazy reason, I decided to try to use the clippers for the last bit, and it broke again. So, I gave it one more try using just the rod saw, and it worked, but we wasted another 2 tiles and a good 30 minutes. So, the lesson of the day is: don’t take shortcuts.

cut around the faucet handle

The last few pieces included the edge pieces to go on the outside corner of the wet wall. We ended up using countertop edge pieces here, which fit very well. I had to cut 2 of them to fit up against the tub, and I ended up cutting the top one a little bit as well, which was another tricky cut with the rod saw. Clare helped me cut the last set of tiles for the top to fit against the sloped ceiling. Then we cleaned up a bit and called it a day.

The tile is on the wall