How to Build a Zinc Tabletop

Zinc tabletops have become popular recently due to their unique look and practical benefits. Zinc is naturally antimicrobial, making it good for kitchen surfaces. It’s also soft compared to other metals, which means it’s less likely to chip glassware or dishes placed on it. In this guide, we’ll walk you through building a zinc tabletop, from selecting materials to applying the finishing touches.

Tools

First, gather the following tools.

Preparing to Build Your Zinc Tabletop

Once you have the needed equipment, clear a well-ventilated workspace large enough for your table. Gather your zinc sheets, plywood, table base, and tools. For an industrial-style piece, consider using a machine-age cast-iron base, which can often be found for less than $75 at online marketplaces. You could also use premade table legs, such as the Nipen legs from IKEA, which cost about $15 each. Consider turning a wood slab into a table and topping it with zinc to blend natural and industrial styles.

When choosing a base, don’t overlook creative salvage options. In one This Old House project, the builder explored several inventive base ideas — jet-age-style legs found at a recycling center, inexpensive gas pipe from the home center, and even cast-iron fireplace surrounds from the Victorian era. As the builder noted, gas pipe offers “sort of that industrial feel” while being cheap and readily available at any home center. Matching salvaged base materials to your tabletop’s era can give the finished piece a cohesive, storied look.

If you’re building a new table, make sure the base is sturdy and level. If you’re working with an existing table, clean the table of debris. Sand down rough spots and fill holes or cracks with wood filler. 

Measure your table surface carefully, adding an extra 1-2 inches on all sides to allow for wrapping around the edges. Using your measurements, cut the zinc sheet to size with tin snips. Work slowly and steadily to ensure straight, clean cuts. If you’re new to working with sheet metal, you should practice on a scrap piece first.

How to Build a Zinc Tabletop: Step-by-Step Instructions

Below we provide step-by-step instructions on how to build a zinc tabletop:

Step 1: Attach the Zinc

Load the caulk gun with heavy-duty construction adhesive and glue a thin sheet of zinc to the plywood top. Apply a thin, even layer of adhesive to the table surface, working in small sections to prevent drying before you can place the zinc. Be sure to cover the entire surface, especially the edges.

Lay the zinc sheet onto the adhesive-covered table surface, starting at one end and slowly lowering it to avoid air bubbles. Use a clean cloth to smooth it from the center towards the edges, pressing out any air. Flip the piece over so that the metal is on top, and place quick-grip clamps along the edges for a secure hold while it sets. You can also use heavy books or weights across the surface to keep the zinc flat.

Step 2: Cut the Corners

When dry, use a utility knife to score the metal along all four edges for folding. Using tin snips, make a diagonal cut in the zinc at each corner, from the metal’s outermost point to where the corner of the wood starts, creating two triangular flaps. Repeat on all four corners.

Step 3: Bend the Edges

Starting along one side, use a flat 12-inch chisel covered with a clean cloth or rag to bend the zinc around the edge of the wood. Work slowly, moving along one side at a time. Use a dead blow hammer to help smooth the crease and create a tight fold. When the metal is well-creased, glue it to the plywood edge.

Technique Detail: When bending sheet metal to a 90-degree angle, keep in mind that the metal will spring back slightly after you release pressure. To compensate, bevel your clamping surface about 8 to 10 degrees so you can bend the metal past 90 degrees — it will then spring back to a clean right angle. As one This Old House project demonstrated, a homemade brake made from two pieces of 2×8 clamped together with this bevel works perfectly for achieving tight, consistent bends.

Step 4: Wrap the Corners

To finish a corner, wrap one triangle of zinc around the plywood edge. Wrap the opposing triangle of zinc on top of it and snip off the top triangular piece of metal. Repeat until all four sides and corners are done.

Step 5: Solder the Corners

Key Technique: The secret to a strong, clean soldered joint starts with proper surface preparation. According to This Old House Magazine, you should thoroughly clean and polish the surfaces to be joined beforehand—use fine-grit emery cloth to polish the metal until it’s bright, and avoid touching the cleaned surface afterward, as oils from your fingers can prevent the solder from bonding properly.

When the soldering gun is hot enough, hold it in your dominant hand and pick up the coil of lead-free solder with your other hand. Place the straight tip of the coil on the rough zinc edge at one corner and touch the tip of the gun to the coil to join the metals. For a smooth and uniform joint, hold for 3 to 4 seconds, then remove the coil before removing the tip of the gun. Repeat on each corner of the table. 

Use a metal file to even out the soldered corners and smooth any rough edges along the table. Take care to avoid scratching the zinc. When finished, polish the surface with a soft cloth.

Zinc Tabletop: Adding Decorative Elements

Add copper rivets along the edges or inlay other metals for contrast. Experiment with how to build a three-tiered side table and apply zinc to each level for a multi-dimensional effect.

A Note on Riveting: If you’re adding copper rivets to your zinc tabletop, skip pop rivets. As copper artisan Drew explained on This Old House, “Pop rivets are a little weak and kinda spin on their axis, so they’re not a good solution.” Instead, hand riveting — the same aviation technology used to build airplanes — provides a stronger, more secure hold for metal-to-metal connections.

Why Zinc Patinas Naturally: Zinc doesn’t require a man-made coating to protect it from the elements. Instead, it naturally generates a protective patina of metallic oxides, produced continuously as the metal reacts with air and water. As This Old House Magazine has noted, these oxides are what “render zinc’s steely brightness a freckled gray.” Given enough time, the material could last a century or more before fully oxidizing away.

Zinc develops a patina over time due to the metal oxidizing. If you like the look and want to speed up the process, you can apply a patina or antiquing solution. Clean and dry the surface afterward to prevent damage.

Troubleshooting Common Issues

Here’s how to address some common problems when making a zinc table:

• Bubbles or lifting: You can usually fix bubbles or lifting by injecting a small amount of adhesive under the lifted area with a syringe. Press and weigh the area down until the glue dries.
• Scratches or dents: Buff out minor scratches with fine-grit sandpaper. For deeper scratches or dents, use a metal filler designed for zinc. Apply the filler, let it dry, then sand it smooth to match the surrounding surface.

Caring for Your New Zinc Tabletop

Proper care will keep your zinc tabletop functional and help it develop a beautiful natural finish as it ages. Follow these care tips:

• Wipe the surface with a damp cloth and mild soap for regular cleaning. For tougher stains, mix baking soda and water.
• Avoid using harsh chemicals or abrasive cleaners. 
• Always dry the surface thoroughly to prevent water spots.