With that experience in mind, Mark Sawyer of Tom Sawyer Enterprises in Albuquerque, New Mexico, really caught my attention when he talked about the rash of full-height, coved jobs that his company has installed recently-on time and at a profit.
Even more impressive is the fact that one of those jobs had a two-inch decorative border that ran around the perimeter of the tops, up the wall and across the top of the splash.There was an appliance garage located in one corner against which the backsplashes were butted on either side, and an undermount sink was installed in another section of the top.Sounds like a lot of cutting and fitting on the jobsite, eh?Not for Sawyer
."We just brought them in and set them on the cabinets," Sawyer
said."Everything lined up perfectly-even the electrical cut-outs that we did in the shop."
"A major reason for our success is that our templates are very accurate, and we have the confidence to follow them exactly when fabricating in the shop," Sawyer
company uses a type of stick-built, thin plywood template system that is commonly found in solid surface shops around the world."We rip quarter-inch plywood into two-and-a-quarter inch strips, lay them out on the cabinet frames and hot glue them together," he
"First we build the deck with a one-inch high cove," Sawyer
explained."Then we locate and cut the field joints."Sawyer Enterprises
uses a Striebig panel saw to cut and machine the field joints on the finished deck-all in one pass of the saw."It really works quite well and is quick to do," he
said.Once the decks are ready with field joints cut, the backsplashes are loaded onto the panel saw and the horizontal joint where it meets the cove is cut.The backsplash field joints are offset about an inch from the deck field joint, in order to make the installed top stronger.
"When gluing up the backsplash we clamp the decks together and seam everything, including the field seam on the splash," Sawyer
said."Once the vertical pieces are clamped, and before the glue sets up, we unclamp the deck seam, break the backsplash field joint apart and clean the glue off of the joint."Sanding and finishing then proceeds in the normal way.With all of the minor details taken care in the shop, installation is usually a breeze.Sawyer
company typically charges about twice the price for a job with a full-height backsplash as it does for a typical installation."It seems like all of sudden we have these people who are asking for full-height, coved jobs," he