Access Panel Dilema
I need to build an access panel for this tub area. The area of the panel is 32" x 30" (shown in red). The panel will have 8 pieces of tile on it, grout lines shown in blue for reference.
I am trying to figure out the best substrate to use for the base panel to which the tile will attached. The base panel can be no thicker than 1/2". Initial thought is plywood, but I am worried about it bowing after I mortar the tile to the panel
. If you paint a wood panel on one side it will eventually bow. I assume the same is likely to happen if I adhere tile to one side of a wood panel. My friend suggested that I coat the entire panel in HydroBan to completely seal it and thus prevent bowing.
It sounds like a plausible solution but would feel better with some experienced feedback.
So the questions are:
1) Is plywood the best substrate to use?
2) Is thinset the best way to adhere the tile to the panel or should I be looking at something more like an adhesive?
3) Would coating the panel in Hydroban prevent it from bowing?
4) Another friend said I should get a really large tile and use it as a backing panel (certainly stiff enough). Other than the final panel being heavy as hell, I would think there is risk of shattering?
Thanks for any feedback.
Whatever material you choose, you might be able to buy yourself some extra rigidity and may bow protection by cheating and laminating two rectangles on the back side of the panel that fit into the the two rectangular openings. If you have a spare 1/2" available inside you would now have a 1" thick slab over about 75% of your panel. Or you could go really nuts and start out with 1" material and route 1/2" deep channels for the framing members.
Of course the plumbing looks good enough you could just put in plexiglass, sign it and call it art.