Building a corian countertop.

This information is from an actual build of a corian countertop. Photos were taken along the way. I will be as clear as possible on all the steps needed to accomplish this.

We are lucky enough to have a CNC for the cutouts. Laying them out on cad is extremely cost effective. If you dont have one you can use a mock-up piece you cut from plywood first.

We have to make 6 countertops for corporate office lavartories. Three sinks each, with a high gloss finish to match existing granite.

Lets start this project.

1. First you recieve and ensure the product has no defects. If so, try to still utilize maximum product by cutting around the defects. Circling the with a magic marker helps later on so you don't forget where it is on what pieces. On this project we had six counters to make, so it can get confusing. After all this is accomplished start laying the job specs out on a full size piece of shop ply. This will ensure you have adequete room for hardware, sinks, and anything else that can get in the way.

2. After your full size layout is in order and everything works it's time for cad (or a mock-up). Laying out the project now should be easy. you already have a shop ply layout, now its just a matter of copying that info into the computer.

3. Once the cad is set you can go ahead and run another piece of ply to ensure the machine is setup properly. You dont test with the actual workpiece, that stuff is pricey and the boss won't appreciate a $700.00 error from bad math. Once a perfect model is cut move on to the next step.

    note: Ensure you calculate material for backsplashes, aprons, and build up

4. Now you can actually cut the corian to the proper depth and width. We used a panel saw and we leave everything big by a 1/4". A router will be used later to make a nice clean cut that will be much easier to sand.

5. At this point you'll want to make some space and setup a bunch of saw horses and I-Beams. I like to lay them out in a paticular fashion, like a kitchen, so my work space isn't spread out all over the shop. When it comes to routing and sanding you won't walk 20 miles after an 8 hour day. This is the trick of a master.

   * Set it up so the height is comfortable for you and you wont be slumped over all day. This is common practice and I shouldn't have to explain that here.

6. Once you start machining the tops, cut slower than recommonded, this helps with chipping out and  chatter. After one top is cut, unload it and place it on you workspace and load the next one in the machine. Cut everything at the same time, one after another until all of them are cut. When you finish, your work area will be full and ready for the next step. Not to mention the boss likes the look of orginization.

7. Now it's time to bring the tools. Grab three routers(this is best so you don't continually change bits and have to re-adjust your heights.) You'll need a big router 3 1/4 HP is fine, A medium router 2 HP, and two Trim routers (yup the one for laminates).

   Set up all these routers together see photos below for a visual.

four bits you'll need are:

   A: 2"H x 1"D  pattern bit

   B: 2"H x 1/2"  flush cut bit

   C: a 1/4" round over bit

   D: A 1/4" trimming bit

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