Expedition Evans · video

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Fabricating custom galley countertops for a salvaged sailboat requires building new surfaces from scratch to accommodate narrow, 18-inch deep dimensions.10:43 The project involves cutting plywood to size, installing custom fiddles to secure items during passage, and routing edges to prevent sharp corners.4:55 To save weight compared to stone, the crew uses plywood sealed with high-performance epoxy.17:29 A narrow, off-the-shelf sink is rotated sideways to fit the limited counter depth.10:49 The process includes using a laser-cut template for precision, sealing the freezer lid against condensation, and applying thickened epoxy to bond the fiddles without visible screw holes.14:04 The final finish involves a decorative marble-look epoxy pour, requiring careful surface preparation, sanding, and radius-rounding of all edges.16:35 Proper prep work, including testing router techniques on scrap wood, ensures the final epoxy application remains durable and aesthetically consistent.11:31

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