Great advise from my previous post, and would like to express my appreciation for you all taking the time to post.
I played around with a practice top and learned much from my mistakes. I need to bend the laminate around a 1.75″ radius. I found that sanding the back side and heating it up with a hair dryer did the trick for me, but is that the proper way of doing it?
I installed the sides first and then the top. When I trimmed the top the with a flush cutting bottom bearing router bit, the bit also cut some of the side as well. Was the bit adjusted too low? Should it only be adjusted lower enough to cut the top? Also, can I use a 7° bevel to trim it or first cut the bulk with the flush bit then clean up with the bevel bit?
Also I had to place a seam on the side of the top. How do you get a nice tight seam that can barely be seen? I am using white, so I know that is probably the hardest seam to hide.
Thanks to all who respond.
Woodrow
Replies
I just finished making three countertops -- far from being an expert, but this is what I learned...clamp both pieces side by side with just under 1/4 inch between them, set up a straight edge so you run a trim bit between the two pieces. Any slight variation off the straight edge will be mirrored in the other piece and they'll still fit tight.
Jim, do you mean overlaping them by about 1/4"? Also, does the laminate vibrate as you are cutting it because you can not clamp right to the edge?"One measurement is worth a thousand expert opinions"
Woodrow
Not trying to jump in here on Jim, but, if you are going to use a 1/2" bit space the two pieces about 1/4 to 3/8" apart so that you are taking some off both pieces. The weight of the router on top should keep the laminate from vibrating, make sure the two pieces cant shift while you are routing.
Also when you put these pieces down in order to get a very tight fit that is hardly noticable glue one down completly and on the second piece with your dowels under the laminate, line the mated pieces together, now pull the first dowel closest to the joint out, then skip the next one(this is the tough part) then go along and take the rest out as you normally would.
Now go back to the one that you left in, take it out and roll it out, this will push the joint tight, the trick is knowing how much to leave skicking up, to much and you cant roll it out, to little and it doesnt do any good.
Hope this makes sense, I made up a lot of counter tops before I was shown that and what a difference it makes.
Doug
Edited 5/20/2003 11:34:10 PM ET by Doug@es
Doug,
Thanks for your reply. You make perfect sense and I understand the seam joining technique you are describing. Thank you for your input. "One measurement is worth a thousand expert opinions"
We've had good success with heating a steel/iron pipe of the required radius with torch or oven (if small enough pieces) for bending lam for private jet interiors we've done.
I'll try and find spec.s or my mind (memory) for temp.s and process. It really worked well, and even worked with the high gloss lam.s we used in the construction of galley units, etc, cheers,Phil.If it is to be.... 'twil be done by me.
You have plenty of info for the seam, heres some for the edge.
Standrard high pressure lam is only recommeded for a 4" radius. you can get vertical grade or postforming grade which will bend tighter but most times it's a PITA getting it and you have to buy large pieces. Your right in sanding it but I've had more then 1 develope verticle cracks in the radius months after installation. It's a risk.
When trimming the deck laminate use the bevel cutter. You cut into the edge because it wasn't prefectly square. After trimming clean the edge up with a file.
________________________________
Thanks guys, all the info has been very helpful. I actually did bend standard Formica around a 2" radius, but after three tries. I did sand the underside to thin it out but the heat really did the trick. I spent most of a beautiful Sunday playing around with laminates. I certainly learned much from my mistakes.
Heating up a steel pipe and then bending laminate around it sounds like a great idea. I would like any other info you can provide on the technique if any comes to mind.
Regards"One measurement is worth a thousand expert opinions"