Solid Surface Countertop

[kmdonlin]

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 Rotax 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.

 

[#Tee]

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

 

[kmdonlin]

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?

 

[Billedis]

[member=51654]kmdonlin[/member], That is a beautiful job.  Have been wanting to try solid surface, so appreciate the links to where you purchased.  Bill

 

[tjbnwi]

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

 

[tjbnwi]

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

Tom

 

[kmdonlin]

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. 

 

[morgan]

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.

 

[kmdonlin]

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.

 

[tjbnwi]

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.

[member=47173]Brent Shively[/member], could you ask Steve to post his sheet on how to create a 3 piece cove solid surface backsplash?

Tom

 

[Peter_C]

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

 

[Brent Shively]

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.

[member=47173]Brent Shively[/member], could you ask Steve to post his sheet on how to create a 3 piece cove solid surface backsplash?

Tom

[member=4105]tjbnwi[/member] 
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

 

[tjbnwi]

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.

[member=47173]Brent Shively[/member], could you ask Steve to post his sheet on how to create a 3 piece cove solid surface backsplash?

Tom

[member=4105]tjbnwi[/member] 
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

 

[mike_aa]

[member=51654]kmdonlin[/member]

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.

 

[Jasonj888]

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.

 

[kmdonlin]

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.

 

[blaszcsj]

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.

 

[jimbouk]

Nice job. What's grits and types of abrasives did you use?

 

[sae]

[member=37561]#Tee[/member]

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

 

[#Tee]

[member=37561]#Tee[/member]

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

ahh thanks for clearing that up! i always wondered what solid surface was all about.