Solid Surface Countertop : First Project

[Brian Livingstone]

Hi,

I am thinking about a countertop made out of Formica- this is a solid surface countertop.  I need a 72 by 24 inch countertop for my laundry room.  I have access to a 84 by 30 inch slab of Formica.  As I understand it, I would rip the Formica to 24 inches wide and 74 inches long.  I would glue a piece to the exposed bottom edge.  Clean up the edge with a router.  I would need to cut a hole in the countertop for a top mount sink. 

I am thinking my TS55, OF1400 and Carvex would be up for the challenge.  I have never used solid surface material; can anyone who has worked with this material advise on whether my tool arsenal is sufficient, and it seems to me that it should not be overly difficult.

Thank you.

Brian

 

[Brice Burrell]

My experience with solid surface fabrication is very limited so I won't give any advice beyond saying you've got tools that will do the job. 

 

[Sparktrician]

The tools you're suggesting seem to be quite adequate for cutting to dimension.  Your material is 1/2" thick, so you'll want to do your rough cut of the material leaving an inch on all sides.  Cut your substrate to finish dimensions minus 1/2" on the front and minus 1/2" on sides that will be exposed so you can add finish drops of 3/4" to make the countertop appear to be 1-1/4" thick.  Now do a finish-quality cut using the TS 55 on a guide rail to straighten the solid surface material edges to final dimensions.  From the cutoff pieces cut a 3/4" wide piece which will be bonded under the front edge of the countertop and two 3/4" pieces for the sides.  Bond the countertop to the substrate holding the substrate back 1/2" from the front and 1/2" back from the sides to leave room for the front and side extensions.  Let the adhesive set up.  Then you can bond the front and side extensions holding them in place using a ton of spring clamps until the bonding agent sets up.  Your Formica dealer can help you with the appropriate bonding agent.  Once it's all set up, you can trim it as needed using your router and a 1/4" round-over bit for the edges.  From here, you can put the desired finish on the Formica material either before or after you  cut the hole for the sink.  Be aware that the countertop will be very vulnerable to breaking in the region of the sink where the material has been cut away, so have several people available to help you gently ease it into place.  I've attached a schedule of abrasives document that is based on Steve Bace's instructions given during the Solid Surface class in Henderson.  You'll need a good sander like the RO 125 or RO 150 and a matching size ETS 125 or ETS 150 to bring the material up to the desired level of polish.  Be sure to turn the suction 2/3-3/4 of the way down on your DE and use only the minimum pressure on the sander.  Let the tool do the work.  In this case, the abrasive and sander constitute the tool.  Putting too much pressure on the tool or having the DE suction up too high will result in swirl marks in the finish.  Complete the finish on the material before setting your sink, too. 

 

[JeromeM]

Just a piece of information Formica isn't solid surface and solid surface isn't Formica

Solid surface is a man-made material usually composed of marble dust, bauxite, acrylic or polyester resins and pigments. It is most frequently used for seamless countertop installations.

http://en.wikipedia.org/wiki/Solid_surface

Formica laminate is a brand of composite materials manufactured by New Zealand-based Formica Group. The material was discovered in 1912, and is manufactured for a variety of applications today. In common use, the term Formica refers to the company's classic product, a heat-resistant, wipe-clean, plastic laminate of paper or fabric with melamine resin.

http://en.wikipedia.org/wiki/Formica_(plastic)

So the information and advice would be different depending on the material you have.

If it is a substrate with a Formica laminate then the substrate could be MDF, MRDF, chipboard, or a MR chipboard. So the tools you have should be enough. If a solid surface I would defere to advice from others.

 

[Sparktrician]

Jerome, Formica has created a line of solid surface materials over and above their long-standing line of laminate products.

 

[tjbnwi]

Just a piece of information Formica isn't solid surface and solid surface isn't Formica

Solid surface is a man-made material usually composed of marble dust, bauxite, acrylic or polyester resins and pigments. It is most frequently used for seamless countertop installations.

http://en.wikipedia.org/wiki/Solid_surface

Formica laminate is a brand of composite materials manufactured by New Zealand-based Formica Group. The material was discovered in 1912, and is manufactured for a variety of applications today. In common use, the term Formica refers to the company's classic product, a heat-resistant, wipe-clean, plastic laminate of paper or fabric with melamine resin.

http://en.wikipedia.org/wiki/Formica_(plastic)

So the information and advice would be different depending on the material you have.

If it is a substrate with a Formica laminate then the substrate could be MDF, MRDF, chipboard, or a MR chipboard. So the tools you have should be enough. If a solid surface I would defere to advice from others.

Formica is a brand not a material.

Tom

 

[JeromeM]

Jerome, Formica has created a line of solid surface materials over and above their long-standing line of laminate products.

I stand corrected [unsure] as should the Wikipedia entry :