Ep53 - We built a new lightweight countertop (From Scratch)
We remove a heavy Corian galley counter and build a lightweight replacement from Coosa board and fiberglass—learning carpentry lessons along the way.
Episode Overview
Some refit projects start with a clear plan. Others start with removing something and immediately asking, why on earth did anyone build it this way?
In this episode, we begin replacing the galley appliances—which means the old countertop has to come out. That’s when we’re reminded just how heavy Corian really is. Once it’s off the boat, it’s hard to imagine why anyone would choose it for a performance-oriented catamaran.
So instead of replacing it with something just as heavy, we decide to build a new lightweight countertop from scratch, using Coosa board laminated with fiberglass. Strong, durable, and dramatically lighter—exactly what we want aboard.
📺 Watch Episode 54 👉
Constructing a custom lightweight galley countertop using Coosa board and fiberglass on a cruising catamaran.
Tearing Out the Old Counter
Removing the original countertop quickly turns into a reality check:
- Corian is much heavier than it looks
- Weight adds up fast on a multihull
- What works in a house doesn’t always belong on a boat
Once it’s out, there’s no going back—we’re committed to building something better.
Designing a Lightweight Replacement
The goal is simple: reduce weight without sacrificing strength or function.
We choose:
- Coosa board as the core material
- 1/8-inch fiberglass sheet laminated on top for rigidity
- A layout that supports new appliances while keeping things simple
This is very much a “measure twice, hope for the best” kind of project.
Pretending to Be Carpenters
Neither of us claims to be fine woodworkers—but that doesn’t stop us from trying.
In this build we:
- join sections using biscuits
- create drop edges to give the counter a finished look
- test-fit everything repeatedly to make sure it actually belongs on the boat
Does it look perfect?
If you squint… absolutely. And more importantly, it’s strong, light, and exactly what this refit needs.
Why This Project Matters
This countertop is more than just a surface—it’s a foundation for everything that comes next in the galley.
It’s also a reminder that refits are full of moments where you:
- learn as you go
- try things slightly outside your comfort zone
- accept “good, strong, and lighter” over “perfect”
And honestly, that’s kind of the point.
In This Episode
- Removing the original Corian countertop
- Discovering just how heavy it really is
- Designing a lightweight replacement
- Building a counter from Coosa board and fiberglass
- Biscuit-joining panels and forming drop edges
- Test fitting and committing to the build
What Comes Next
With the new lightweight countertop built, the next step is turning it into something that actually feels finished. In EP54, we take this raw structure and transform it with a custom epoxy resin pour—turning function into something genuinely beautiful.
