Tuesday, December 11, 2018

Kitchen Sink and Garbage Disposal Replacement Adventure

It's been a white hair project!  I should have known better when it's time to call for the professional plumber and being so hard headed.  It's been two months now since my garbage disposer died.  I should have just replaced the garbage disposer and got it over with.  But I wanted to switch to a single bowl large sink.  All my baking pans and pots can be quite large.  I got tired of turning the pots and baking sheets over and over and spilling water all over the counter.   My wonderful thought about having a single bowl sink is becoming a not quite so wishful though.   I finally found this 33" x 22"single bowl kitchen sink with 4 holes from Amazon.  It's beautiful.  I was 100% sure that the measurement matches exactly as my old two bowls sink.   The new Ruvati sink came with a model card board in the shipping box.  All I had to do is to drop into my sink frame and if it fits, then, supposedly the sink would, too.  It placed in perfectly, but when I tried to seat the new sink in, the reality  - Oh, No.  It doesn't fit.  I had to buy  dremel tool, attachments - thanks to Holiday sales. Hours of cutting tiles, adjusting, and shaving of plywood frame to the counter top.  Who would use concrete or the cement to attach Tiles to the kitchen counter.  What a luck.  It took HOURS to slice them through to remove tiles.  And of course, the reality of how the Lenar builder built my kitchen sink frame / counter is a shocker.  "The thing" that we should not see, but expected to had been completed perfectly is now exposed.  More shaving, more tools.  New battery pack, new garbage disposer.  And Oh, Dear.  All the returns and more purchases I had to do.  But what can you say other than a salute to professional plumbers.  But after seeing how my sink is built - "sigh...."
This is my photo diary of the replacement thus far.  It is not completed as of today, and I cannot install the garbage disposer I purchased because its rubber disposer guard and neck threading and lower mounting ring are manufactured with defect.  It made it impossible for the low mounting ring to slide lock onto upper mounting ring. Arrg!

Every Garbage Disposal Instructions from hardcopy to online and YouTube tells you to just Twist and turn the lower mounting ring around the unit's collar clockwise  to dismount the garbage disposal.  Really?  I tried and tried.  WD40 to pounding with hammer.  Nothing.  After two and half weeks of trying (not every moment, but after work, spare moments...), I used my neighbor's 5 lb sledge hammer. Pound on it about 10 times as hard as I could.  Nope.  Not a budge.  In despair, as my neighbor asked if I want him to take a look at it.  He said, he has no experience with plumbing at all or with the garbage disposer.  I was already frustrated for the day, so I said, "Sure."  He arrived at my messy kitchen with tools everywhere.  He looked at the unit.  In a moment of him twisting the unit, out he came under the sink cabinet holding the garbage disposer unit.  I was happy at the same time felt so dismayed.  I think I screamed in fright that it happened.  But it's out.  He didn't even do anything.  Arrg!
This is the new garbage disposer purchased at COSTCO.  I was going to replace the broken unit with this one.  Sadly, the unit was too large.  The design of the new single bowl sink designers did not put it into account for the position of the original wall drain pipe location nor how the pipes clearance are under the sink for two bowls sink.  Sadly, I had to return it.  But I got to study the mounting ring around the neck of the unit and how it operates.   But did my garbage unit dismount as easy as it says?  it was a nightmare 

 My broken unit.  Looks the same and as easy to twist slide to dismount.  Naaa.  It was a nightmare. 

Sure.  Looks so easy when it's brand new.

 No sign of movement.
 Won't budge.  I used tire jack to hold the unit up.
(From this picture, there is plenty of room between garbage disposer and main wall drain pipe.  But after I installed the new sink... the truth sunk in.)
 I decided to remove all retaining screws.  And sprayed like tons of WD40, then, borrowed neighbor's sledge hammer.  Did it move?  NO.   It's already two and a half weeks.  Give me a Break!!
 There it is.  After my neighbor friend came in just to check and see what I am talking about.  He barely tugged and twist on it.  Out it came in his hand as he was holding a baby.  Arrg!

 See all that WD40?
 Now to take off the flange.  Need to take off that retainer ring.  I practiced first on the new unit first before I returned it.  (The new unit was too long!! the drain pipes were in the way!! Arrg!)

 Pop! the rest came off.

Push up the flange.

The Arrival of Ruvati Single Bowl Kitchen Sink in Triple Pandora Packaging. 

  Very well packed.  No Dents anywhere.  
After the reality that the counter top tiles need to be shaved off, time to purchase tools.  Luckily they were all on sale.  Do I know how to use it?  I know how to use a drill.  ... and thank goodness to the  YouTube and Instruction sheets, etc.   
It's a bit challenging to squeeze those two side bars in to disconnect the spinner head control.  Had to dig my thumb and index fingers in to disconnect.   This tool is pretty heavy, but sturdy.
And thank goodness, the tool attachments were on sale, too.  Choose the head for Tile work.
To unlock the control head's attachment lock, pull up and pull back down,  it says.  Yep, that was easy.

Then, attach the right tool head... I think this is incorrect.  The tool's locking wheel needs to face down and flash against the tool.   Because when you depress the power, it would not spin.
When attached correctly, each pin head would poke through the tool head's wheel spoke.
Then, flip the front head stopper horizontally.
Lift the Lock handle up and push it back down.
Cover up all kitchen area or remove them from the kitchen.  Or, suffer the micro dust from the sawing of caulk and concrete.
Wear a Goggle and Micro Dust Mask - ready to slice down the caulk.  
Thank goodness I have Rainbow vacuum cleaner.  I used the regular bagless vacuum cleaner to vacuum up all this micro dust.  I did not see any caulk or cement dust accumulate in the container.  Later, I found out that they are all in the air filter.   And I am glad that I use it first anyways before I used my Rainbow.
After a good while of cutting, I used a Mason Chisel and gave some gentle tapping with sledge hammer to remove the tile.
I thought I needed them after the new sink is installed.   So, I marked each tile.

I thought these initial cut is sufficient clearance for the new sink.
Learning how to remove all the sink parts.  Taking photos as a record.

Now that all pipes are detached underneath, it's time to remove the sink.  I bought a crow bar to help me give a lift.  I guess you could just lift it up by holding the holes of the sink.  Oh, well.  I need one for the home, anyways.... I don't know for what, but....I got one now.
Ta, daaa.... Oh, My Gosh.  A hideous surprise.  How in the world the workmen passed their supervisor's okay to put in this jagged plywood as counter top for sink's frame - that I don't know.  I was so disappointed.  So, after a few days of air dry, I used a wood glue and visor to glue them together as much as I can.  Then, I saw them down as straight as possible.

REALLY? and what are those?  They are not MASTIC adhesive.  They are cement/concrete.  Really?
Ticked me off.

Thank goodness to this RIDGID tool, I manages to shape and shave the concrete clean as much as possible... later, eventually.

If I were you - call the Professional Plumber. 
So, here we go . . . Installing the new sink's flange that came with the new garbage disposer. . . Really?

Looking good, but No Cigar. The garbage disposer - Badger 1 - supposedly is 11-1/4" long or 11-1/2" long is too long.  The main wall drain pipe is in the way!!
Modification is to pop the sink drain flange up and try to install the garbage disposer unit.  Then let it sit.  There should be 1/2 inch clearance between the garbage disposer unit and wall drain pipe, but the new garbage disposer came with manufacturing defect.  The rubber disposer splash guard is somehow is crooked, and would not allow the lower mounting ring to run up the upper mounting ring together.  Hated to return it.  But there is nothing I can do.  Changed the drain flange to Ruvati sink manufacturer's original flange.
(Pics to follow.)
 A camera shot from under the sink to install faucet unit.  Yep, the hole is large enough for the screw nut to through and for my hand to tighten it.
  Attaching faucet sprayer unit
Snap in the end.  There is only one way to go in.  Follow the faucet installation guide's instruction.

In Pumping motion, pump the handles of pipe cutter to cut.  To open the handles, just pull it outward to open.
 Putting dishwasher's aerator back in in place.  (I wish I have a new dishwasher... a wishful thinking.)

 I think I need to check the original photo record.  I think I got the washer wrong.
 Trying all kinds of parts to accommodate the original piping manufactured by Charlotte Piping and Foundry Co's DWV 1-1/2" pipes.  The original pipes under my sink is in great condition.  So, I hate to replace them, if I don't have to.  But since the pipes are in the way of installing the garbage disposer, maybe an alternative piping is required.  But all these plastic or PVC type look like they are  going to last only a year.
 Tried to put back the original tailpiece to the sink drain flange, then, I took it off and tried SnappyTrap's.  But the SnappyTrap is too long, and it require cutting.  No problem in cutting, but I have to be 100% sure before I commit to cutting anything.

 The black pipings are the original.  Here in the pics are without the Tee pipe that connected to the two bowls sink.  No I need to modify it to connect the single bowl sink.  Seems easy, but I don't want to just do it.  I want to make sure that what I do would not violate the code.

 This particular P-Trap has screw nut attached to the 90 degree angle pipe that attaches to the P-Trap.  The ordinary 1-1/2 inch P-Trap does not fit either.  It needs a P-Trap with ridged connector inside.
 This is how it looks without the tailpiece pipes to the two bowls sink drain.
If I want to install the garbage disposer, the solution may be to cut at the wall drain pipe and install new pipes so they are out of the way of the garbage disposer.   The question I have is that could a 16 gauge single bowl large sink handle garbage disposer hanging?  Or does it need a small support built for it to hold it up from underneath? 

To be continued.