I like the look of granite counter tops but not the cost ($75-$150 $can/sq ft). I made this one out of granite tiles for $3.99 can/sq ft using tiles from Home Depot. Another advantage of tiles is that I can handle the counter without any help since the tiles are loaded when the counter has been fitted.
The base is 3/4 in ply and the two sections are but joined using three counter clamps (since the gap is not visible). The edge is trimed with a custom oak ply cap.
The oak ply cap is applied first, and used as the reference for the height of tiles. the rear of the ply cap is rebated to allow a 1/4 lip to ride on the bottom of the ply base so that the cap is referenced to the ply bottom.
I decided to risk gluing the cap on without using any brads to hold it while the glue set up. I used ratchet clamps and a striaght piece of 1x1 to get an even pull accoss the cap
The tiles are butted with no gap so as to approximate a granite sheet. Each tile has 4 screws which are used to compensate for the tile to tile variation and get a smooth top. The screws are nominally set so that they sit 1/8 above the ply surface and adjusted for each tile to get a perfect surface. The tiles will be held with blobs of silicon caulking rather than thin set morter.
Normally a wide grout spacing is used to hide tile to tile differences but in this case differences in height are quite visible and you can feel them. In addition some tiles were cut at a slight angle and others had a significantly different thickness -probably having been cut at a different time.
I am still toying with how to grout the small gap between tiles and any suggestions will be appreciated.
Each tile has a 1/16 chamfered edges giving a vee shape between the tiles of 1/8 in by 1/16 in deep.
I plan to mask around the joints and force either a transparent epoxy or silicon into the joint using a blade. I don't want the material to come loose or degrade over time.
Caulking is not normally recomended for gaps less than 1/8 in but maybe forcing it in with a blade might give the long lasting seal that I need.
Bryan