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Cutting laminate.

Fox | Posted in Construction Techniques on February 8, 2003 04:40am

WHAT ARE SOME GOOD TIPS & TOOLS OR CUTTING FORMICA SHEET STOCK.  Especially for out lets  and around windows.

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  1. Adrian | Feb 08, 2003 05:19pm | #1

    Templates, flush trimming bits and laminate trimmers (indispensable) for things like outlets. A tablesaw or a laminate knife for straight, through cuts.....a laminate slitter (handleheld) does a great job of cutting strips with clean edges...something like $150 Cdn. but well worth it if you're doing a lot.

    cabinetmaker/college instructor. Cape Breton, N.S
    WAY too conservative to be merely right wing

    1. Fox | Feb 08, 2003 07:06pm | #2

      How well does a laminate router with a 1/8 " straight cutting bit used with a straight edge on a table work for cutting out a layout.

      1. InspectorBob | Feb 09, 2003 02:13am | #4

        How well does a laminate router with a 1/8 " straight cutting bit used with a straight edge on a table work for cutting out a layout.

        That's a great way to cut large pieces. Or...

        You can try an over-cut bit, which is a 1/4"-straight carbide bit with a 5/8" bearing mounted on the bottom. Clamp the laminate to your edged blank (or whatever you are covering), and run the trimmer around the blank. Your laminate will have a uniform 3/16" overhang.

        Bob 

        1. geob21 | Feb 09, 2003 03:26am | #5

          Roto-zip

  2. DaveHeinlein | Feb 09, 2003 01:58am | #3

    Look for *downcut* jig saw blades. They take a little getting used to, but they work pretty well. Bosch makes them, prolly others.

  3. Mooney | Feb 09, 2003 07:21am | #6

    What Adrian said  mostly. I have done pretty well playin with angle grinder for outlets that are metal. A zip bit makes short work over a plastic box.

    Tim Mooney

  4. Turtleneck | Feb 09, 2003 09:35am | #7

    The worst thing that can happen is the  "Big Split", you know, when you hear a little 'click' and then it sounds like someone is opening a zipper? If you make any inside corner cut in formica you are just begging for a split. I make all of my cuts from the back side of a well supported sheet with an "Olfa Laminate Cutter", it looks alot like a utility knife with a small hook on the end. Richards, makes a carbide cutter, but I prefer the Olfa hands down. After making any inside cut use a ¼"round file at the intersection and you will stop the sheets tendancy to split.

    Try:http://www.olfa.com/Products.asp?C=4&P=58

     Turtleneck

    If your sitting at a poker table and can't tell who the sucker is... its you.  Paul Newman



    Edited 2/9/2003 1:43:13 AM ET by Turtleneck

    1. DaveRicheson | Feb 09, 2003 02:34pm | #8

      Just curious, are you laminating directly over drywall for a full splash in a kitchen? Existing or new construction?

      Dave

      1. Fox | Feb 09, 2003 05:59pm | #9

        This job is and existing job were a new top is being installed with a new color so the back splash full height has to be covered this will be the third layer. The first layer was installed directly to the sheet rock and the second layer over the first just using laminate. Looks like they used liquid nail to attach it.

        1. DaveRicheson | Feb 09, 2003 09:19pm | #10

          I have done a couple of overlays like that. I used a thinset mastic between the layer, rather than contact cement. Gave me a lot more time to get it in place. with contact cement you need to get everything right the first time, or have a heat gun handy if you don't. Windows w/o the cassing were just rough out with a hand liminate trimmer. Scribed the corners first and then lay out the cut for the recpt. boxes.

           I made a new base for my laminate trimmer from a peice of 1/4" luan. Cut the new base a few inches over size and lay out the screw pattern. Install on the trimmer w/o a center hole cut, and then use a paneling bit to plung through the new base plate.. After that sguare up the base using one side and the bit as a reference. My set back form th edge of the bit ended up being 2" each direction. Build a jig for the box size and cut it out witha jig saw. The hole for a 2x4 box  for my set up is 6x8 ". I marked center line referance on the face of the jig and line them up with my layout lines for the box. If the box is a little out of plumb it is easy to line up you index lines. Lay the new laminate on a piece of plywood with a larger hole cut in it and clamp the jig, laminate and backer board all together. Plung cut at the center of the new box opening and follow the jig with your custom base. Works like a charm. I have jigs for several differnt size boxes that I keep in my router cabinate. Maybe I'll get another one of those overlay jobs agian some day.

          What are you doing to cover the raw ends of the laminate at the end of a cabinate line?

          Dave

          1. Fox | Feb 10, 2003 12:03am | #11

            What I think i will do is rabbit out a cap to match the wood work or cabinet color.

    2. Adrian | Feb 10, 2003 03:38am | #12

      Inside corners HAVE to be radiused (straight form the mouth of the manufacturers); if that corner gets cut square, any stress, and there it goes, like you say.....same with solid surface, etc. That's why I use templates and router bits when possible....automatic radius. Just have to stop the apprentices from filing them square and 'purty'.cabinetmaker/college instructor. Cape Breton, N.SWAY too conservative to be merely right wing

      1. calvin | Feb 10, 2003 04:24am | #13

        Adrian, long time.......hope all is well.

        When I rough cut laminate, I'll drill a 1/2" hole (with an old style Stanley "spur" bit, cuts on the edge, with a backer behind it) at the inside corner layout.  Cut to the circle with a circular saw.  Quick and easy on site.  Had problems in the field trying to support that 5x12 floppy plastic and routing with jigs.  Luckily there's a few ways to skin a cat.__________________________________________

        Remodeling Contractor just outside the Glass City.

        http://www.quittintime.com/

        1. Adrian | Feb 11, 2003 03:02am | #14

          Calvin....dagnab it....there I thought I knew everything, and you go and teach me a trick. Sure yer not Canadian?cabinetmaker/college instructor. Cape Breton, N.SWAY too conservative to be merely right wing

          1. calvin | Feb 11, 2003 05:26am | #15

            Adrian, (if you're not joshin me)  you're a shop guy, you don't need tricks.........you built them in that shop.  In every inconceivable stinkin' tight spot with b***s**t always in the way and no real easy way to do it, you gotta come up with some tricks.

            As to that bit, I don't think stanley makes it anymore.  It had a forstner kind of cutter and a spur on the edge that would cut through the lam.  No danger of blowing the cut apart.  Spose you could use a brad pt. or a hole saw.

            Not canadian that I know of, just close to the border.  Might be the water.

            Have a good week.__________________________________________

            Remodeling Contractor just outside the Glass City.

            http://www.quittintime.com/

          2. Adrian | Feb 11, 2003 02:59pm | #16

            Not joshing....good trick.cabinetmaker/college instructor. Cape Breton, N.SWAY too conservative to be merely right wing

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