How to Make a Shower Pan from Scratch

Building a shower pan from scratch can be a rewarding and cost-effective project for bathroom renovations. It involves meticulous preparation, precise measurements, and the application of specialized materials. Follow this step-by-step guide to create a durable and functional shower pan tailored to your specific needs.

Step 1: Gather Materials

Shower drain (with a flange)
Shower pan liner (PVC or acrylic)
Mortar mix (pre-mixed or dry-mix)
Concrete backer board (backer board screws and washers)
Joint tape (alkali-resistant fiberglass mesh)
Thin-set mortar
Ceramic or porcelain tiles
Tile adhesive
Grout (matching color to tiles)
Leveling spacers
Safety equipment (gloves, goggles, and dust mask)
Tools (tape measure, level, utility knife, trowels, hammer, drill, and grout float)

Step 2: Prepare the Subfloor

Ensure that the subfloor is level and free of any debris or irregularities.
If necessary, use a self-leveling compound to create a smooth and even surface.

Step 3: Install the Shower Drain

Position the shower drain in the desired location, ensuring proper alignment with the drainpipe.
Apply a generous amount of sealant around the drain flange to prevent water leakage.
Secure the drain in place with the provided screws or bolts.

Step 4: Install the Shower Pan Liner

Carefully unfold the shower pan liner and place it over the subfloor, ensuring that it fits snugly around the drain.
Trim any excess material with a utility knife, leaving about 4-6 inches of overlap onto the wall studs.

Step 5: Apply Mortar Bed

Mix the mortar according to the manufacturer's instructions.
Spread a thin layer of mortar over the subfloor, ensuring that it is evenly distributed.
Press the concrete backer board firmly into the mortar bed, starting from one corner and working your way out.
Screw the backer board into the subfloor through predrilled holes, using washers to prevent the screws from pulling through.

Step 6: Apply Joint Tape and Thin-Set Mortar

Apply alkali-resistant fiberglass mesh joint tape over the seams between the backer board panels.
Mix thin-set mortar according to the manufacturer's instructions.
Apply a thin layer of thin-set mortar over the joint tape, ensuring that it is completely covered.

Step 7: Install the Tiles

Spread a thin layer of tile adhesive onto the back of each tile using a notched trowel.
Press the tile firmly into place on the wall, ensuring that it is level and aligned with the adjacent tiles.
Insert leveling spacers between the tiles to maintain a consistent grout joint width.
Continue installing tiles until the entire shower wall is covered.

Step 8: Grout the Tiles

Mix grout according to the manufacturer's instructions.
Apply the grout to the joints between the tiles using a grout float, ensuring that it is fully packed.
Remove excess grout with a damp sponge, wiping diagonally across the joints.
Allow the grout to dry completely before sealing.

Step 9: Seal the Shower

Apply a silicone sealant around the base of the shower where the pan meets the wall.
Apply a sealant to the joints between the tiles and the shower pan liner.
Allow the sealant to dry completely before using the shower.

With careful planning, precise measurements, and a bit of elbow grease, you can successfully create a shower pan that meets your preferences and ensures a watertight and durable installation. Whether you're a seasoned DIY enthusiast or a first-timer, this step-by-step guide will help you achieve a professional-looking shower pan that will last for years to come.