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great thread!
I just finished my first countertop (a vanity top approx. 5'x2' with a couple of jogs in it). I built the forms out of melamine, and used foam in the bottom of the form for a recess for the cabinet. I used quikrete countertop mix which i liked alot, and had pretty good luck with a palm sander for vibrating. My one regrettable mistake was mixing the material with a shovel instead of a mixer. I ended up with one small dime-size chunk of dry pack that ended up flaking out. I repaired it by mixing portland, color, and bonding agent (which worked fine).
One bit of advice i would add for patching/filling pits/etc. though, is make sure you dont spread the patching material over to much of the countertop. On my project it left a really light stain that soaked in a bit, and had to be ground out later.
......might try a coat of penetrating sealer before patching next time.
...anyone try that?
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