With all the new waterproof membrane systems I was originally planning to use a preformed base covered with membrane, either Kerdi or Noble systems. However, my floor area is 36 X 48 inch and the preformed units are 48" sq. If I cut them down then must deal with re-establishing the proper slope. Could go with a mud base and cover with membrane. Came across what I thought was the ticket in a tile ready plastic pan with intergrated drain (by Tile-redi), after reading comments by others found there were too many problems with flexing and tile pop. These new membrane kits are expensive @ 400 -$600 per shower. Any suggestions?
I saw a great custom shower job on the DIY network. (Bathroom renovations or sweat equity) It was very simple. They created a form and nailed thick EPDM liner to the studs. They chalked a line and poured concrete. They sloped it from the chalk line to the drain. Then they sealed the concrete. I think with some type of epoxy sealer. They tiled up the walls. Cheap ($100?) and easy custom shower.
Hey I found it:
http://www.diynetwork.com/videos/pouring-a-custom-shower-base/49992.html
They estimate $100-$200. They have four articles on the subject on the website.
Better video.
http://www.diynetwork.com/videos/custom-shower-base-fabrication/20883.html
I made a custom bath and a shower pan in the UK for my old house
They were made out of 3/4" marine plywood bases and 1/2" sides with drainage set in
all glued and screwed to support bars.
Then stained - and two coats of boat resin apllied to it.
It lasted about 5 years untill the hard water spoilt the look - just could not get it clean any more- chucked the bath away as was never used
So I tiled over the ply and its been 5 years more.
Frankly there is no reason that it should ever fail unless flex sets in