I was recently approached by a customer looking for a unique, one of a kind inlay. She wanted a pattern to match the grout in her tile backsplash. Now I have matched tiles, cabinets and wall color, but never “Tile Grout”. The customer had a sample from a poly resin mix with mirror chips of blue glass. The basic idea was to add a design to match the grout color and still add a bit of style with mirror chips.
Follow the steps below to get started creating unique, interesting inlays without expensive tools or a CNC router:
| STEP 1: The most important step in the entire process is laying out the pattern. Pay close attention to get straight lines and make sure they are parallel to the front edge. |
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STEP 2: After laying out the pattern, glue straight edges to the deck with hot glue. You will need to make sure you have a continuous straight edge to make one pass. It is not recommended to start and stop the pattern. Take extra time laying out the straight edges for a perfect slot.
The slot can be as wide as you like and at least a 1/4" deep.
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STEP 3: Time to get out the "Mad Scientist Table". You will need to gather up the following supplies:
- Grout
- Mirror
- Clear Epoxy Inlay
- White Latex Paint
- Section of Material with groove
- Mixing Cups
- Mixing Sticks
- Hot glue gun
I started by crushing the grout into a fine powder. I also crushed the mirror making sure the chips are smaller than the groove.
Mix the grout with a little of the latex paint, creating a ketchup type consistency. Grout/Paint ratio is 90/10. Mix just a little to test the color. The color will darken when you put the resin over the grout. This is why the test piece is so important.
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STEP 4: Now that we have the grout fill and the crushed glass, it is time to pour it into the groove. Mix plenty of inlay grout fill material. You don't want to run out in the middle.
Start at one end and fill the bottom third of the slot. Do not overfill. This will leave no room for the mirror chips and resin.
Pour in the mirror chips. Create the best look by flipping some of the mirrors face up while leaving some face down.
Allow the grout fill to dry completely. Leave overnight for best results. If you pour in the resin too soon, it will lift the grout to the top.
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STEP 5: Now that the grout is dry you need to dam the perimeter of the groove to contain the resin fill. I like to use hot glue. It is easy to apply and even easier to remove.
Use any clear resin fill you typically use. Slowly pour the resin into the groove. I like to fill it above the counter surface to allow the air bubbles to come up above the groove.
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STEP 6: After completely dry, spray hot glue with alcohol. The glue should peel right off, leaving the resin.
Ski route the protruding resin fill and sand even with the deck. Finish sand using your normal sanding procedures.
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Here is the finished inlay. It should be rich in color with plenty of depth. The glass chips make a really nice accent with visual interest.
Some green designers might say this was Eco friendly because I used their old tile grout. It was a small percentage of the overall project but the material was Avonite Cozumel which has 40% recycled content.
Good luck with your next inlay project. If you have any questions or comments, please do so below.
About the Author: Gene McDonald is the owner and operator of Refresh Interiors Inc. in Pinellas Park, Florida. Refresh Interiors specializes in "GREEN" countertop fabrication/installation. McDonald can be reached at refresh@knology.net Visit his website: www.gotgreencountertops.com |