Hi chassis. The sink is made from a single sheet (1200x2400mm or 8 x 4 feet) of 3/4 inch construction-grade plywood. I started with a full sheet of plywood (8 feet by 4 feet or 2400mm x 1200mm) and gave it two coats of epoxy on both sides before I cut out the pieces. After making the joins (rebate, wood glue and nails) I mixed filler with epoxy to make an epoxy mix with the consistency of putty, then applied fillets that strengthen the joints and make them fully waterproof. After that I applied several more coats of epoxy. Not pretty up close, but very effective - the plywood is fully encapsulated in epoxy so in theory the moisture content in the ply will never change so it should be dimensionally stable. No sign of any problems so far after 18 months of regular use.
For the drain hole I bought a flanged drain outlet at the hardware store, and bonded it into a recess in the floor of the sink with epoxy. I made the recess in the base of the sink with two holesaws - first cut half-way through the base to the outside diameter of the drain fitting, then cut all the way through with a small holesaw the size of the drain pipe. Then carefully remove the waste with a chisel. Apply a good coat of expoxy to the exposed plywood and let that harden up before bonding the drain fitting into place with more epoxy. Careful work with the epoxy will ensure that the wood never gets wet.
The final dimensions are approximately 670mm (front to back) x 2400mm long, and the sides are 150mm high.
Cheers!
Bookmarks