The unconventional kitchen design required the counter to be a custom made, stainless steel fabrication. The counter was delivered in two pieces and needed to be joined on site. Bob Watts, from Granite Metal Services, gave Bob a few pointers on spot welding a field joint. There are two steps to spot welding, a rough and a finish step, and attention to detail can produce a beautiful welding job.
The counter's dimensions allowed a smooth delivery and the counter was placed 15 degrees from the loft wall and ready to be welded. First, Bob Watts prepared the weld by putting a joint flat plate on the underside to take away some of the heat and clamping the field joint together. The equipment required for this welding job used TIG (Tungsten Inert Gas). This was chosen over other welding materials for its finite stick weld—in layman's terms, a weld as fine as a ballpoint pen. Before the welding began Mr. Watts gave Bob a few safety tips.
A long sleeve shirt to protect the arms from burns was donned. Eye protection is very important in welding and a dark welding helmet protects eyes from the damaging light that the torch gives off. When welding, water can control the heat to keep the metal from distorting. Where the rough step brings the metal together and keeps it in place, the finish step makes the difference between a merely functional welding job and the sleek, seamless appearance Watts and his crew were able to achieve.
A steel rod was used as filler in the joint where the two pieces did not quite meet. A die grinder with carbide bur tip was used to give the bullnose a uniform look. To produce the shine that matches the rest of the counter, the polishing wheel was dressed with rouge. With the field weld achieved, the counter was ready to be moved into position. Bob, with a little help from the "men of steel", snuggled the counter into place. With the stainless steel counter installed, the diner style kitchen is one step closer to completion.
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