----- Original Message -----
From: "Rich White"
> What should I use to make the two cuts? I have a skill saw, jig
> saw, hand saw and a router to choose from.
For cutting to length, cut from the bottom if using the skill saw
(turn the counter top upside down). That way the blade is cutting INTO
the laminate surface which will minimize chipping/damage of the
surface. Fasten (clamp or screw) a guide to make a straight cut.
Will the cut end be against a wall or cabinet? If so you may want to
make a cardboard or thin plywood template to get the fit right before
cutting (i.e. it is unlikely to be at exactly 90 degrees to the long
edge). If the end of the counter is visible don't forget to plan for
any desired overhang and glue on a finished end cap. Rout/file that
for a smooth finish.
For the sink cut-out I usually drill holes of the desired radius for
the corners (a hole saw work well) then connect the holes with either
a skill saw or jig saw. Be wary of chipping of the laminate (use a
sharp blade and don't cut too fast) but the sink lip should cover that
OK. I will slip a clean piece of cardboard under the base of the saw
to avoid scratching the counter top's surface. Do the cutting while
the counter is in position as cutting it out of place has two
problems: 1) the counter top will be weakened where the cut out is so
carrying it into the kitchen is a disaster waiting to happen. And B)
you need to make sure the cut out is in the right location anyway.
BTW, support the cut out so that it does not break off/fall through as
you are nearly done making the cut. Screw a cleat or two across the
top (placing the screws into the part that becomes the scrap...) for
support.
Eric Russell
Mebane, NC
http://home.mebtel.net/~ejrussell
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