So I talked to Darin this evening about Formica, a lot of good hints. First, you need to cut the raw stuff oversize, then use a flush cut router (a straight router bit with a bearing the same size on the end, need to get one of them, need it anyway) to trim it to fit. Use contact cement (got that) on each piece to secure. Start with the two end edges, then the front edge, then the top, so it all gets covered and doesn’t leak. Best to use a router table (have one) so not to slip and cut into the plank at the wrong angle, better to keep it a little on the clear side. You can cut Formica on a table saw with a fine tooth blade, but keep the blade high so it cuts down as the stuff tends to float. The problem is lining it up, that’s why you cut it oversize and route it to fit. On the top, to get it even, use slats to hold it apart with the contact cement on it, line it up, then pull a slat and press it down, pull another and use a roller to press it even. Keep doing that until its down and smooth.
On the sink cutout, fine tooth blade on the jig saw, tape all the cut lines and draw the pattern. Tape the back of the saw (good idea) to prevent scratches. Drill a hole to start the cut on each end and cut it just the ends. Screw a board across the middle scrap section with a couple screws to hold it up as the final cut clears, then finish cutting the long sides and pull it out with the board. Any small chips will be covered with the sink edge. Use a fine file to trim the outer top edge to an angle, always filing down, when the paper ruffled under side falls off its there. Wow, that’s valuable information, thanks to Darin Scott.

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