The Finished product
Beginning to sort
Friends and family saved their caps for 5+ years specifically for this project. These are beer caps from domestics, craft & import.
Free labor 🙂
Getting the kiddos involved sorting the caps.
Caps sorted by HUE
Basically tried to bucket them into ROYGBIV. I have no idea how many, but this took a bit of time.
Custom bar top
Here is the bar top after assembly. Two large pieces of quality 5/8″ plywood form the base. The rails are 1 1/2″ poplar, and were notched with a table saw and hand routed. The whole assembly was glued and nailed.
Freshly painted bar top
Painted matte black with several cans of Rustoleum. The finish does not have to be perfect since it will be covered in epoxy.
Freshly installed bar top
This was taken immediately after the bar was put in it’s final position. It needs to be as close to perfectly level as possible, otherwise the epoxy resin will “pool” in low spots.
The first of several iterations
Let the games begin! The initial concept was to lay out an image comprised of bottle caps, then reality set in and we opted for the much easier gradient effect.
To be fair, this took several attempts because of numerous factors: visually, it wasn’t as cool as I wanted it to be. Also, we had a lot of black caps, but few bright blue (for example), so laying them down “evenly” was challenging.
Unfortunately, once the caps are down, attempting to move them results in disaster due to the caps shifting/overlapping each other. So, the process would begin all over again if it wasn’t right. At one point we attempted adhering them to the bar top with spray adhesive, but that ended up looking terrible not to mention messy.
It took a few restarts before we were satisfied with the distribution and overall visual.
Finally starting to make some progress
It took at least 4 hours and several restarts to get to this point.
Variety is the spice of life
Epoxy + activator
Since epoxy is fluid, it takes the path of least resistance, which we later found out. Ensuring drop cloths/cardboard and cleanup towels are in place if you attempt this!
Filling in the gaps
Topping it off
Getting the bubbles out
From the corner, left
From the corner, right
Another view of the finished product
I am so proud of this project. It is a real conversation piece and we did it together true DIY