Author Topic: Solid Surface Countertop  (Read 6628 times)

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Offline kmdonlin

  • Posts: 10
Solid Surface Countertop
« on: September 27, 2015, 11:26 PM »
I have embarked on a project of making some countertops for my dental practice.  It is done with LG Hi-matics solid surface because of the color and price.  I got the material out of Solidsurface.com.  The seaming adhesive used is from Gluewarehouse.com.  The Festools used are TEQ 55 saw with solid surface blade.  This combination of saw and blade is probably the best thing for cutting solid surface and getting smooth cuts with no chip out and silky smooth cuts.  I also was using Rotex 90 and 150 for sanding and finishing.  I was also using 1400 router with various bits the one for doing the sink cut out was a CMT solid surface bit that has a nylon bearing and works well for cutting out the sink and not marking out the sink.  It leaves a small overhang for a nice finish. 
Clamping was done with 4" PVC solid core Sch 40 and 6" schedule 40 for the bigger clamps.  If more tension is needed double up the clamps.  I did one deck seam on the L-shaped piece.  That was clamped with wood blocks hot glued to the surface and then clamped with 2 c clamps and one PVC clamp.  The one pic shows the deck seam.  Nothing fancy.  Anyone had any questions feel free to ask.  I am just learning as I go.

Festool USA does not pre-approve the contents of this website nor endorse the application or use of any Festool product in any way other than in the manner described in the Festool Instruction Manual. To reduce the risk of serious injury and/or damage to your Festool product, always read, understand and follow all warnings and instructions in your Festool product's Instruction Manual. Although Festool strives for accuracy in the website material, the website may contain inaccuracies. Festool makes no representations about the accuracy, reliability, completeness or timeliness of the material on this website or about the results to be obtained from using the website. Festool and its affiliates cannot be responsible for improper postings or your reliance on the website's material. Your use of any material contained on this website is entirely at your own risk. The content contained on this site is provided for informational purposes only and does not constitute professional advice.


Offline #Tee

  • Posts: 718
Re: Solid Surface Countertop
« Reply #1 on: September 28, 2015, 12:26 AM »
very nice work! what router bit did you use for the sink cut out? and can the ts cut granite/quartz?
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Offline kmdonlin

  • Posts: 10
Re: Solid Surface Countertop
« Reply #2 on: September 28, 2015, 09:10 AM »
http://www.amazon.com/CMT-880-572-11-Surface-Overhang-Diameter/dp/B010URJVK2/ref=sr_1_1?ie=UTF8&qid=1443445758&sr=8-1&keywords=CMT+sink+bit
Is the bit used for the sink.
I am unsure on the Quartz material.  The granite I am pretty sure no.  Most of that material is cut on wet cutting diamond blades. 
Thanks
very nice work! what router bit did you use for the sink cut out? and can the ts cut granite/quartz?

Offline Billedis

  • Posts: 570
Re: Solid Surface Countertop
« Reply #3 on: September 28, 2015, 09:46 AM »
@kmdonlin, That is a beautiful job.  Have been wanting to try solid surface, so appreciate the links to where you purchased.  Bill

Offline tjbnwi

  • Posts: 4864
  • Cedar Tucky Indiana
Re: Solid Surface Countertop
« Reply #4 on: September 28, 2015, 10:31 AM »
very nice work! what router bit did you use for the sink cut out? and can the ts cut granite/quartz?

Definate no on the grant. Quartz, not well, very hard on the blade.

Tom

Offline tjbnwi

  • Posts: 4864
  • Cedar Tucky Indiana
Re: Solid Surface Countertop
« Reply #5 on: September 28, 2015, 10:34 AM »
kmdonlin, the inside corner is to square. Inside corners must have radiuses.

Tom

Offline kmdonlin

  • Posts: 10
Re: Solid Surface Countertop
« Reply #6 on: September 28, 2015, 09:10 PM »

kmdonlin, the inside corner is to square. Inside corners must have radiuses.

Tom
Hey thanks for the info. I will get that done. I came across Wilsonart's solid surface installation manual and it explained the proper seaming protocol. I have more countertops to fabricate and will do it there. 

Offline morgan

  • Posts: 39
Re: Solid Surface Countertop
« Reply #7 on: September 29, 2015, 08:33 AM »
This bit is perfect for getting a nice radius on the inside corner without using a radius jig.

http://www.amazon.com/gp/aw/d/B000K2AGX4?vs=1

It has a lot of mass for excellent cuts in solid surface and it has a large diameter.

Offline kmdonlin

  • Posts: 10
Re: Solid Surface Countertop
« Reply #8 on: October 12, 2015, 09:46 PM »
Here are some photos of the countertops installed and put to work. Turned out pretty well. Would probably do it again.


Here is the L shaped countertop installed.
Here is the support bracket I had a local welding shop fabricate for me.

I have to install new flooring.  This is an ongoing remodel in my office.
Here is a before pic to see where I was coming from.

Offline tjbnwi

  • Posts: 4864
  • Cedar Tucky Indiana
Re: Solid Surface Countertop
« Reply #9 on: October 12, 2015, 10:08 PM »
Looks good for the first set you've done. The backslash is normally coved, Steve Bace has a method to do it without special tools.

@Brent Shively, could you ask Steve to post his sheet on how to create a 3 piece cove solid surface backsplash?

Tom

Offline Peter_C

  • Posts: 415
Re: Solid Surface Countertop
« Reply #10 on: October 13, 2015, 02:24 AM »
They look nice :) The color will be good too.

In case you ever want to do a cove here is a nice article. Pretty much how I do them. It is a lot of work and a 1/2" or bigger dowel works for hand sanding the cove.

http://solidsurface.com/countertop-fundamentals/backsplash-coved

Offline Brent Shively

  • Festool USA Employee
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  • Posts: 156
    • Festool USA
Re: Solid Surface Countertop
« Reply #11 on: October 13, 2015, 10:17 AM »
Looks good for the first set you've done. The backslash is normally coved, Steve Bace has a method to do it without special tools.

@Brent Shively, could you ask Steve to post his sheet on how to create a 3 piece cove solid surface backsplash?

Tom
@tjbnwi 
I spoke with Steve this morning and he does his cove back splash the same way that is duscused in the link that Peter C posted.

Brent

Offline tjbnwi

  • Posts: 4864
  • Cedar Tucky Indiana
Re: Solid Surface Countertop
« Reply #12 on: October 13, 2015, 01:21 PM »
Looks good for the first set you've done. The backslash is normally coved, Steve Bace has a method to do it without special tools.

@Brent Shively, could you ask Steve to post his sheet on how to create a 3 piece cove solid surface backsplash?

Tom


@tjbnwi 
I spoke with Steve this morning and he does his cove back splash the same way that is duscused in the link that Peter C posted.

Brent

Thanks Brent, I had never seen that article before. I do have Steve's sheet that he gives out for the class.

Tom

Offline mike_aa

  • Posts: 946
Re: Solid Surface Countertop
« Reply #13 on: October 13, 2015, 01:35 PM »
@kmdonlin

So, whats more fun? 

The growl of the OF1400 routing out the solid surface? [eek]

Or, the screech of a drill routing out a tooth? [scared]

Mike A.
« Last Edit: October 13, 2015, 04:27 PM by mike_aa »

Offline Jasonj888

  • Posts: 90
    • Blog about woodworking and family life.
Re: Solid Surface Countertop
« Reply #14 on: October 13, 2015, 03:33 PM »
Excellent work. If you had your practice in my area, I might actually start going to the dentist again. The thought of talking (or hearing about) some quality wood working might soothe me a little.

Offline kmdonlin

  • Posts: 10
Re: Solid Surface Countertop
« Reply #15 on: November 02, 2015, 07:00 PM »

Here is the room completed. I put vinyl plank on the floor and new trim. I have a few finishing touches but I am happy with the the result.

Offline blaszcsj

  • Posts: 265
Re: Solid Surface Countertop
« Reply #16 on: November 02, 2015, 07:33 PM »
I do a different lip stack up than you but overall it looks like you did a lot like I did. It's really assuring to see someone else make something in the same way. Great job! I love working with solid surface.
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Offline jimbouk

  • Posts: 338
Re: Solid Surface Countertop
« Reply #17 on: November 03, 2015, 01:29 AM »
Nice job. What's grits and types of abrasives did you use?
BHC 18, TSC 55REB, OF 1400, MIDI, TS55, TRION, Df500, CSX...

Offline sae

  • Posts: 841
Re: Solid Surface Countertop
« Reply #18 on: November 03, 2015, 02:11 AM »
@#Tee

These are not real stone, it's all acrylic.

Offline #Tee

  • Posts: 718
Re: Solid Surface Countertop
« Reply #19 on: November 03, 2015, 02:20 AM »
@#Tee

These are not real stone, it's all acrylic.

 ahh thanks for clearing that up! i always wondered what solid surface was all about.
When youre feeling depressed just treat yourself to a systainer even if its a mini systainer its ok.

IG: tee212

Offline Peter_C

  • Posts: 415
Re: Solid Surface Countertop
« Reply #20 on: November 03, 2015, 03:47 AM »
ahh thanks for clearing that up! i always wondered what solid surface was all about.
Solid Surface is often known under a trade name from Dupont called Corian. There are many other brands that now manufacturer solid surface materials, in lots of colors and patterns.

Remarkable stuff  [big grin] All my counter tops at home are Corian, and my guest bathrooms floating vanity is a one off bent up Corian fixture. In fact so is the light fixture, that holds a recycled sea shell. The material can be heated and bent like the plastic it is, yet works very similar to wood. Better is it can be glued, and if done carefully the glue lines disappear. Repairs can be performed including cutting sections out and replacing them. Cleaning is easy enough. The material can be sanded to 500 grit, or mirror polished. It is a non permeable surface so good for doctors offices and food prep. The only bad thing is the material is expensive.

Offline kmdonlin

  • Posts: 10
Re: Solid Surface Countertop
« Reply #21 on: November 06, 2015, 09:56 AM »

Nice job. What's grits and types of abrasives did you use?
I used festool abrasives 120, 150 180 220 then festool vlies A280 and A800. The vlies is what makes the seams disappear and the shine come back. I took these tips to a matte only. These tops are wiped down with harsh disinfectant multiple times per day. Matte finish hides the blemishes nicely. 

Offline Tayler_mann

  • Posts: 411
Re: Solid Surface Countertop
« Reply #22 on: November 06, 2015, 09:59 AM »
very nice work! what router bit did you use for the sink cut out? and can the ts cut granite/quartz?

I was actually told by a Festool rep that the TS75 in partnership with a special blade can cut granite

Offline lunchman

  • Posts: 76
Re: Solid Surface Countertop
« Reply #23 on: November 06, 2015, 10:10 AM »
Nice work. And it's good to see another Big Steel Keg owner, but you need to get that grill dirty! (I've got a Bubba Keg which is the BSK predecessor) ☺Grilling is my other passion.

Offline kmdonlin

  • Posts: 10
Re: Solid Surface Countertop
« Reply #24 on: November 06, 2015, 11:44 AM »

very nice work! what router bit did you use for the sink cut out? and can the ts cut granite/quartz?

I was actually told by a Festool rep that the TS75 in partnership with a special blade can cut granite
That would be cool and a beast mode. The only problem is nothing else to work with the material. Needing water cooled router to round over the edges or cut sink hole.
Very cool to see what festool comes up with.
Solid surface material is fun to work with due to similar working properties as wood and forgivable nature of the material.

Offline kmdonlin

  • Posts: 10
Re: Solid Surface Countertop
« Reply #25 on: November 06, 2015, 11:47 AM »

Nice work. And it's good to see another Big Steel Keg owner, but you need to get that grill dirty! (I've got a Bubba Keg which is the BSK predecessor) ☺Grilling is my other passion.
I love to grill and smoke also. Just time is on commodity I don't have enough of. Kids activities and work get in the way of my hobbies.

Offline kmdonlin

  • Posts: 10
Re: Solid Surface Countertop
« Reply #26 on: January 03, 2017, 10:40 PM »
Back fabricating more countertops. Nice thing is that these are all straight runs. Coving BS create tons of dust and chips. All of the tops have sinks in them. Smells like a nail shop in a strip mall when gluing up the pieces. Will post more photos later.
Cheers


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Offline Peter_C

  • Posts: 415
Re: Solid Surface Countertop
« Reply #27 on: January 04, 2017, 02:43 PM »
Really I am trying to help...If I had not had mentors and people helping me learn thru life, things would be a lot harder :)

Oh man that got coved a little deep, and is going to require a lot of sanding. Put an edge guard on a Rotex with a hard pad and start at 80 grit. You are going to need to blend it well. If the edge guard allows the sander to get too close to the cove use an 1/8" strip of material with double stick tape on it. The outside round over also got cut a little deep. Easier to blend in though just use a soft pad, slow speeds and when pushing over the edge use a foam interference pad.

Another good thing to do is to "Fake in" the sharp outside corner. Meaning take sandpaper and by hand smooth it further. Using a sheet strip not backed, working it like buffing a shoe, will help keep the roundness.

Also run a router over the backsplash outer edge. You can even double stick tape something onto it cove it a little if that makes sense?

It will look great once sanded out :)

Offline RickyL

  • Posts: 68
Re: Solid Surface Countertop
« Reply #28 on: January 07, 2017, 10:03 AM »
Looking good,

Why use PVC for clamps? Why not just use clamps?
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Offline kmdonlin

  • Posts: 10
Re: Solid Surface Countertop
« Reply #29 on: January 07, 2017, 10:06 AM »
Looking good,

Why use PVC for clamps? Why not just use clamps?
I don't have enough clamps to provide enough clamping pressure across the entire countertop. I don't feel like spending 1000 in clamps without a plan to keep using them. I think I am into the pvc for like 50 bucks.
Cheers


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Offline Job and Knock

  • Posts: 76
Re: Solid Surface Countertop
« Reply #30 on: January 07, 2017, 10:29 AM »
Only thing I'd say is that if you were doing a lot of Corian work you'd probably end up burning out that 1400. I killed two DW625s working it before moving onto an OF2200EB. Corian is a real router killer
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Festool USA does not pre-approve the contents of this website nor endorse the application or use of any Festool product in any way other than in the manner described in the Festool Instruction Manual. To reduce the risk of serious injury and/or damage to your Festool product, always read, understand and follow all warnings and instructions in your Festool product's Instruction Manual. Although Festool strives for accuracy in the website material, the website may contain inaccuracies. Festool makes no representations about the accuracy, reliability, completeness or timeliness of the material on this website or about the results to be obtained from using the website. Festool and its affiliates cannot be responsible for improper postings or your reliance on the website's material. Your use of any material contained on this website is entirely at your own risk. The content contained on this site is provided for informational purposes only and does not constitute professional advice.