Jun 25 2009
Laminate a Countertop #2
Carefully measure and mark the sheet of plastic laminate to the approximate size of the countertop; it should be large enough to overhang the counter 1/8 to ¼ inch on all sides. Use a carpenters’ square and a straightedge to make sure the marks are accurate. Plastic laminates are very brittle; wear safety goggles to trim the laminate sheet. Support the laminate sheet firmly as close to the cutting line as possible; hold it down firmly to prevent shattering and chipping. Carefully and slowly cut the sheet as marked with a saber saw, a circular saw, or a table saw with a fine-toothed carbide-tipped blade. Cut the laminate face down with a saber saw or circular saw, face up with a table saw.
Before laying the top sheet, cover the edges of the countertop with precut laminate edge strips, carefully butted together at the corners. Measure and cut the front and side edge strips to the correct length. Apply contact cement to the back of each edge strip and to the edges of the countertop as directed by the manufacturer, using a nylon paintbrush or a notched spreader. Let the adhesive cure and test for bonding readiness as directed.
Carefully press each edge strip into palce over the cemented ounter edge, first side strips and then front. The bottom of the strip should be flush with the bottom of the edge; let the top of the edge strip stick up above the coun-tertop. You must align the edge strip perfectly as you press it down; once it makes contact with the cemented edge, it can’t be moved. Butt the strips firmly together at the corners of the counter, front strip over sides. After applying each strip, go over it firmly with a roller or a rolling pin to bond it firmly to the counter edge.
Wearing safety goggles, trim the pro¬truding upper edges of the edge strips with a router and an edge-trimming bit for plastic laminates. With a belt sander and a medium-fine-grit sanding belt, sand the cut edges carefully to bring them exactly flush with the counter surface. If the edge strip sticks up only a little, router trimming is unnecessary; use the belt sander to bring the edges flush. Use a fine-toothed flat file to smooth the edge in tight spots.