How to Install Plastic Laminate on Countertops
Invest in Formica for a Bathroom or Kitchen Remodeling Project
Mar 23, 2009
With the global economic downturn, it's more important than ever to save money when possible, and that includes home improvements including bath and kitchen remodeling. Resurfacing countertops is a great investment in home equity; the next best thing to granite, marble, or other natural stone.
Project Tools and Materials
The tool list is relatively basic:
- Circular saw or table saw with fine-tooth blade
- Router with a carbide Formica router bit (with a roller on the tip)
- J-roller
- Contact cement
- Small paint roller
- Masking tape
- Sandpaper and TSP if resurfacing
- Plastic laminate
- 1/4” wood dowels
- Wood file
Preparation for Resurfacing
If the cabinets are not new but are being resurfaced, the first thing to do is remove the sink, faucets, contertop range, etc.
Clean the entire surface with TSP and then sand the surface lightly to ensure proper adhesion. Keep in mind that if the counter has a rounded countertop backsplash, it will not be possible to curve the new laminate at home. A cabinet shop has the proper equipment to do this.
Preparation with New Countertops
For new surfaces, 3/4” plywood works best. The surface should be smooth and level with the good side (no voids) facing up.
Measuring and Cutting Laminate Strips
Like all carpentry and cabinetmaking projects, adhere to the golden rule: measure twice, cut once. In all cases there will be 2 surfaces involved, the horizontal and the lateral.
It's common to measure, cut, and install the lateral strips first. To minimize chipping, apply masking tape where the cut will be made.
Use the paint roller to apply contact cement to both the edge of the plywood and the strips. Carefully apply the strips when the cement gets tacky. Work the length of it with the J-roller to eliminate air bubbles. Get it right; there's no adjustment with this adhesive.
Install the Horizontal Surface
The horizontal is generally straight or 'L'-shaped. 'L' shapes can be cut out of one sheet or more than one piece may be used, butted tightly together.
Take measurements and allow a 1/8” or so (depending on the size of the roller on the router bit) overhang on the outside edges. Carefully cut the material and apply cement to plywood and Formica. While waiting for it to get tacky, lay dowels every foot or so to suspend the plastic.
Position the sheet carefully in place on the dowels. Start at one end adhering the plastic to the plywood. Use the J-roller and work patiently, removing the dowels one at a time.
Finishing Up; Beveling the Edge
Now use the router to slowly remove the overhang and bevel the corners. It may be necessary to allow the bit to cool periodically or it will melt the plastic. Use the wood file on inside corners.
Once the adhesive has set up, the bath or kitchen is ready for use.
