How do I install laminate counter tops? What are some tips/tricks to it?

Question

I'm preparing to install a new laminate counter top in my kitchen; as this is the first I have installed by myself, I would like to know if there are any tip/tricks or things to look out for while doing it?

Specifically, what is the best saw and technique to use when trimming the counter top to length? The counter top has a back splash attached, and I'm not quite sure how to handle cutting it.

What are the best tools and techniques for cutting the hole for the sink, are there any tricky bits to watch out for while doing it?

I know this is a lot to ask for a single question, but I'm looking for the ultimate step by step guide to installing a laminate counter top. Also this counter will be in the shape of an "L", so it would be nice to cover attaching the two pieces and any gotchas associated with that.

Answer 1

Cutting the countertop to length:

Try making a custom circular saw jig to cut your countertop to size. 3/4" plywood placed together at right angles with a cleat for guiding your saw should give you a straight cut. Assemble the jig with extra material, then cut it to size with your saw for a perfect fit.

Use a saw blade with a high tooth count and cut the counter upside down. That way, the blade teeth are traveling down (but really up) into the counter surface, minimizing chances for chipping out. Start by cutting the backsplash first, with the rest of the counter pointing towards the floor. Then stop and rotate the countertop so it's upside down and finish the cut. Be sure to support the cutoff material so it doesn't break off a chunk of the laminate near the end of the cut.

As @auujay points out, masking tape can also help reduce the likelihood of chipping.

Source: woodworkingtips.com

Cutting the sink hole:

I crawled several forums looking for advice on this one. Some suggested techniques (in the order that I would try them) were:

• Use a jigsaw with a down-stroke blade to cut out the sink hole. By cutting on the top surface, you have a more accurate picture where your sink hole will be, and the downstroke blade will eliminate chip-out. Start each rounded corner with a 1/2" spade bit.
• Use a jigsaw with a metal cutting upstroke blade. The finer teeth will make for slower work, but have less of a chance of chipping.
• Use a circular saw to cut straight sides from underneath the countertop. Flip over and finish the rounded corners with a downstroke jigsaw blade.

Once again, use masking tape for both cut line visibility and to reduce the chance of chipping the laminate. Also remember to support the cutout section to avoid tearing the laminate near the end of the cut.

Answer 2

The advise you got about cutting are good. be very careful, use a sharp 60 or 80 tooth blade on a good saw. let's talk about your 45 degree angle now. I sure hope you are buying pre-form counter tops that are precut to the 45 degree angle. Trust me, you cannot do that in the field with any success. There are seven easy steps to jointing a good 45 degree counter top.

Step 1: once stagged in place, apply an even coat of good water proof wood glue (Titebond 2 is ok) over the entire edge of both 45 ends. You want the glue to squeeze out along the entire seem as you tighten in the next steps. this is ABSOLUTELY necessary to keep water from seeping in and delaminating your counters.

Step 2: Install the special spanner bolts into the pre-routed holes under the counter top. Tighten them until the glue just starts to ooze out of the seems.

Step 3: Install a couple of plywood strips (4in X 6in) under the counter top with screws shorter than the thickness of the top. (for obvious reasons) Attach to one section (side) of counter top only.

Step 4: Tighten the bolts until snug and counters meet cleanly. Do not over tighten.

Step 5: Screw the other side of the plywood strips to the underside of the counter top. This will assure a good flush fit.

Step 6: Clean off excessive glue with a damp cloth.

Step 7: Let the glue cure for 24 hours.....Enjoy!