Zinc Countertops?

[kaleokahu]

Maybe it's a longshot, but has anyone put in real zinc, bistro-style countertops?

Sources? Advice?

Mahalo,
Kaleo

[Pedr0]

I've done a small one, wasn't all that difficult. If you're handy and feel comfortable doing it yourself, you can get everything you need from these guys: http://www.rotometals.com/ZINC-SHEETS...

They've also got some videos on how to fabricate a top on their site.

[gliterati8]

Thanks for the tip. Was yours in the kitchen and did it hold up to water?

[Pedr0]

In another life long ago, I was a professional joiner and made the top for a client's kitchen so I can't actually attest to zinc's long-term durability as a work surface. I've seen a number of bar tops in different cities with zinc tops and they all look fine though somewhat patinated. Keep in mind, the stuff Rotometals sells is food-safe but zinc, unlike stainless steel, is a reactive metal so its appearance will change over time.

Other than the soldering bit, the fabrication of the top really was dead easy.

[roxlet]

Ours is in the Butler's Pantry, and includes an integral sink, so it does, indeed, hold up to water.

[GH1618]

I think the bar at Café Claude in San Francisco is zinc, but I may be mistaken.

[BIGGUNDOCTOR]

http://www.zinccountertops.net Try this site for some information.

[kaleokahu]

Thanks, BIGGUNDOCTOR:

The information is useful, but the prices I find... breathtaking. >$3K for a simple tabletop???

I hold out little hope of getting further answer on this, but has anyone done this on a DIY basis? I have a really simple tabletop and the tools and ability to cut the sheetstock. What I'm lacking is a source of the formed edge--hopefully it's available in a nail- or screw-on configuration.

Anyone?

Thanks,
Kaleo

[BIGGUNDOCTOR]

Check the yellow pages for an industrial metal supplier that carries sheet stock. If you can find the material, the edges can be done a few different ways. One is to have a sheetmetal shop run them through a beader. You can have more angular lines done in a brake, or do a combo of the two. Any good sheetmetal shop should be able to do the bending for you, so you would not have to attach the edges. If you do end up attaching them, I would solder them on. Leave a short lip to give you an overlap which will make attaching them much easier.

Another method would be to make a mold, and cast them.

Zinc gives off fumes when overheated which can cause metal fume fever. This is a big subject in my blacksmithing forum . It has lead to some deaths over the years. Drinking milk does not stop it. Soldering should not be a problem, but be careful when casting not to breath the fumes.

Anyone with some basic mechanical / hand skills should be able to do this as a DIY. One thing to watch out for will be electrolysis. Zinc anodes are used to protect water systems, boats, piping, etc. Make sure you have good grounding.

[gliterati8]

You mean when fabricating the sheet, right? It's not a concern once it's a counter, correct?

[BIGGUNDOCTOR]

No, electrolysis will happen anytime that stray electrical currents are around. I have seen iron pipe fittings that looked new, but had holes from electrolysis. Metal hulled boats use zinc anodes bolted to components to help stop this. The zinc being the lesser metal gets attacked first. When it gets used down to a specific point they are replaced. Some large generators use anodes in the radiator to protect the system from corrosion. Look up electrolysis on the net for more info. Corrosion can also be a problem if water is allowed to stand, or if it gets into spaces where it stays wet for extended periods. Acidic foods may also affect it.

[roxlet]

We have a zinc countertop in our Butler's Pantry, and we love it. I don't know where you are located, but we are just north of NYC and it was custom fabricated for us through our kitchen designer. We love it, but I will say that it does take some maintenance to keep it looking shiny. We let ours get a little more funky and worn looking, and it is still beautiful. I'm not sure that I would use it for kitchen counters though. In our kitchen, we have stainless counters next to the stove, and beautiful granite that underwent a process called flaming and wire brushing, which brings out the texture of the stone. No one thinks it's granite..

[kaleokahu]

Hi, roxlet:

Thank you for the information.

I'm not thinking of doing all my countertops in zinc, but I have a chef's table in the kitchen that cries out for it, and it would go well with some of my unfinished quartzite . Is there a recognized fabricator who specializes in zinc tops? I bet there must be, given the resurgence of bistros/bouchons.

I also wonder: Are the 'tops themselves just rolled sheetstock with decorative edges attached later, or are the vertical and horizontal surfaces all done as one-off castings?

Thanks,
Kaleo