I'm in the design stage of making a countertop for a (personal) kitchen remodel and have some questions for more experienced folks than I (before I start cutting boards to length, milling, etc)
The dimensions of the finished counter are roughly 9.5' L X 24-26" W. Starting with 8/4 hard maple and planning to have the edge grain up on finished counter. So the thickness of counter will likely be around 1 3/4" and each piece will be about the same in width (depends on how much needs to come off during milling to get square and flat.) I was planning to rip everything down as described and glue it up with a staggered pattern of short pieces (less than 4') like you'd see with hardwood flooring. I'm wondering if there is anything to consider here other than the finished look with this decision. Alternatively I could use full length pieces (no butt joints along length of counter) for both the full width sections of counter to the left and right of the sink.
There will be a large U shaped cut out in the middle/right of the counter for the under-mounted sink. Roughly 5' of open counter to the left of sink and roughly 18'' of open counter to right. The sink sticks out farther (couple inches) than cabs and counter along the its front edge, but there will need to be a smaller width of counter running behind the sink. By my theoretical measurements, it will need to be roughly 4-5" wide, but likely no wider. My main question is how do I plan that transition from full 24" counter width, down to 4-5", then back to full width again on the other side. Do I try and glue this up all as one unit or do I make it in 2 sections with a joint behind sink (not my preference.) This is gonna be a heavy sucker if all one full length piece...will I have a problem moving an 9.5' x 24" countertop that's only connected in the middle by 4-5" x 32" section? I'm concerned that it would be tough to move, but maybe not?
I plan to finish with multiple coats of Waterlox, so making in 2 separate sections then jointing them somehow in place would be problematic in terms of finishing/sealing that joint. I am planning to mill to final dimensions at my house, then move project to shop space elsewhere due to more space, better tables for assembly and better setup for finishing. With that in mind I have to consider the transport of an 9.5' (or two smaller) finished work piece. Not sure what direction to take here, or if I am over-analyzing this step.
So, with all this background, my main question is how to handle the transition behind the sink and advise opinions on the different options. Secondly, if I made it in 2 pieces and had a staggered? joint behind the sink in the narrow section, how would I join them strongly and accurately and how would the finishing of that section (water-prone area) be affected?
I'm also wondering what some methods are for attaching the countertop to the top of the cabinets to account for seasonal movement of the countertop. Any advice in the arena of wood movement would be greatly appreciated.
I can try and include a sketch of my design if my explanation is unclear. Needless to say, I'm new to a lot of this, but want my project to turn out the best that it can.
Thanks for any help!