How to Install Bullnose Countertop on a Bar Overhang How to Install Bullnose Countertop on a Bar Overhang
Installing a bullnose countertop on an overhang will never be the easiest job in the world. Overhangs are notoriously difficult to get right, as they can easily be over weighted, and come crashing to the ground. Even professional builders are reluctant to take the challenge, and many would rather cut off the overhang, and then install the countertop over the fully supported foundations. If you are particularly determined to have a bar overhang, you should consider installing the countertop yourself. If you have some basic home improvement knowledge, and are prepared to follow some basic guidelines on installation, you should be able to get this project completed within a few hours.
Step 1 - Measure Your Overhang
The first thing that you should do is to measure the size of the overhang. You will need to know the complete length of the foundation which you will be building your countertop upon, as this will ensure that you have the right weights and supports to prevent your overhang from crashing to the ground. Measure the length and width of the bar, and then translate this to the countertop. Using a saw, cut away any excess in the top, and smooth down with some sandpaper. Your overhang should not be more than 12 inches from the last support to the end of the material.
Step 2 - Add Angle Irons
Around the edge of the overhang, screw in some angle irons. Use your drill to push nails into the pre-drilled holes. These angle irons will help to keep the overhang firm, so it is not likely to break off in chunks, or crumble. Secure the last angle iron to the edge of the vertical support. If you do not fit angle irons, you may find that the structure of the overhang is significantly weakened.
Step 3 - Add Corbels
You will now need to add a series of corbels, or brackets, below the line of the overhang. These corbels will serve much the same purpose as they did in medieval times, that is to ensure that the support for the overhang does not end with the last vertical structure, but extends a little way into the horizontal. You will need to have at least one corbel at either side of the overhang, and preferably another two or three in the middle to keep the entire thing upright. Screw in to secure.
Step 4 - Add the Countertop
You can now fit the countertop. Position this so that the overhang supports it fully, but that more weight is held up by the horizontal cabinets from which the overhang extends. Screw down the countertop firmly, with more screws at the supported end than over the overhang. You should not put any weight upon the latter when you are screwing in the countertop.