Plastic laminate is now available in over 90 different patterns and colors and has a multitude of uses around the home. It’s used as kitchen counter tops, bathroom vanity tops, bar tops, etc. It’s very durable and easy to maintain and an easy way to design and construct custom work surfaces. The really nice thing about plastic laminate sheets is that it can be applied directly a top that is already laminated reducing the amount of time involved in reconditioning most surfaces. The old wooden counter tops in Bill and Sandra’s kitchen were ideal candidates. They weren’t standard width so the only other option was going with custom built, preformed counter tops and that wasn’t in their budget. Besides that, they were both ready to learn a new skill set.

Tools and supplies needed

Plastic laminate is relatively easy to work with but a few special tools will make the job even easier.

· Jig saw w/metal cutting blade

· Belt sander w/assorted grit belts

· Router

· Trim router

· Fine cut mill files

· J-roller

· Plastic laminate sheet

· Contact adhesive

· Brush

· ј” dowel rods

Surface preparation

Although contact cement can be applied to almost any surface proper preparation assures you that the laminate will bond tightly and securely to the surface. Without proper preparation the laminate can work itself loose over time.

1. Using a solvent clean the surface thoroughly removing all dirt and grease build-up.

2. If applying laminate over laminate or some other smooth hard surface use the belt sander to rough up the surface before applying the contact adhesive.

Measure twice, cut once

Measure the length and width of the surface to be covered carefully and then cut the laminate sheet 3/8” to Ѕ” larger than the surface. You will trim it to size later using the laminate trimming router or a regular router with a laminate trimming bit installed. The laminate can be cut with your jig saw. Cut the edge banding at this time too, cutting it 3/8” longer and wider than the edge of the surface you will be applying it to. Cutting large sheets of laminate on a table saw equipped with a laminate blade produces the best cuts but the jig saw will work too if you’re careful.

Begin with the edging

Place the edging strip on the counter surface near the edge where it is to be applied. Using the brush apply one coat of contact adhesive to the back of the edging and two coats of contact adhesive to the support edge. Allow the adhesive to dry thoroughly before proceeding. If the strip is a long one it would behoove you to enlist the help of a friend to support it as you align it and press it in place. As a rule, when working with contact adhesive, you will get one shot at getting it right. Contact adhesive is not very forgiving of human error. Once in place, roll it firmly down with the j-roller.

With the edging firmly in place use the belt sander to smooth the top and bottom edges until they are even with the support core.

Applying the laminate top

Lay the top piece face down on the core surface and brush on a single coat of the contact adhesive. After allowing it to dry thoroughly, set it aside.

Using a tack cloth, clean the core surface of any sawdust and then apply two coats of contact adhesive being careful to not allow any of the adhesive to run down on the edging. The best way to do this is to brush the adhesive on by brushing inward from the edges. After allowing the contact adhesive to dry thoroughly place the dowel rods on the core surface at 6” intervals

Carefully place the laminate on top of the dowel rods, adhesive side down. Then, beginning at one end, remove one dowel rod at a time and press the laminate firmly down using the j-roller. Continuing removing one dowel rod at a time as you continue rolling the laminate down until you reach the opposite end. Once the laminate is firmly in place, use the router with a laminate trimming bit to trim the edges of the top piece. A regular router will work but a laminate trimming router is much easier to handle and they are reasonably priced.

After trimming the edges with the router, use the fine toothed mill file to round over the edges, completing your new laminate top.

A word of CAUTION

Contact adhesive is highly flammable and should be used outdoors or in a well ventilated area away from any open flames.

Resources

Materials

Formica Brand Laminate, 800-FORMICA, www.formica.com

Wilsonart International, 800-433-3222, www.wilsonart.com

Tools

Harbor Freight http://www.harborfreight.com/