Wood Working Gurus & Formica

[Bear22]

Guys,

I have a need to cut a L-shaped piece of formica sheet. Cutting the outside edges of the piece/sheet = easy and straightforward. However, it's that inside corner that I am a bit flummoxed with. How does one get as close to 90 degrees without damaging the piece? Any thoughts on techniques (and equipment) to get this accomplished?

TIA

 

[W31Olds]

I'd probably use a Jigsaw with an appropriate blade and cut it from the backside to prevent splintering. Clean up the inside corner with a rasp.

 

[Bear22]

I'd probably use a Jigsaw with an appropriate blade and cut it from the backside to prevent splintering. Clean up the inside corner with a rasp.

Thought about that, but this piece needs to be as fine finished as possible with absolutely precision straight cuts.

I use my jigsaw all the time, but if there is a better method/technique I am all ears.

 

[redfishbluefish]

I'm not sure this is what you're doing, but if it's gluing Formica for, let's say a counter top, what you do is oversize the Formica. Now glue if down using a contact cement. I use multiple dowels between the laminate and wood base to align as close as possible and then start removing the dowels and press down the laminate. Now, using a router with a flush trim bit, trim off the excess. On an inside edge, use a file to remove the round route excess.

Trim bit looks like this:

 

[Bear22]

I'm not sure this is what you're doing, but if it's gluing Formica for, let's say a counter top, what you do is oversize the Formica. Now glue if down using a contact cement. I use multiple dowels between the laminate and wood base to align as close as possible and then start removing the dowels and press down the laminate. Now, using a router with a flush trim bit, trim off the excess. On an inside edge, use a file to remove the round route excess.

Trim bit looks like this:

Yes, I've used these flush bits before with Formica and I have a purpose built file for counter top laminates.

Was just wondering if there is a better (easier) way.

 

[Fish Fan]

Flush trim bit is the easiest way to cut laminate. Using saws can cause it to crack.

 

[Bear22]

Flush trim bit is the easiest way to cut laminate. Using saws can cause it to crack.

Flush trim bits can't cut 90 degree corners ;-)

 

[BeanAnimal]

Yes, I've used these flush bits before with Formica and I have a purpose built file for counter top laminates.

Was just wondering if there is a better (easier) way.

To be sure, is this going to be glued down prior to trimming, or are you trying to finished as a raw sheet for some reason?

If it is glued down, then the accepted finish step would be the flush trim bit as tight as you can. Be mindful of the bit rotation direction so you don't get tear-out. Then use a very sharp straight edge and razor to mark the exact inside corner line so that when you carefully file toward it it wont chip out. Use painters tape right up to the line for further protection. You have to file vertically, only downward or you will notice the difference in bevel or create chips on the up stroke.

 

[Freenow54]

Thought about that, but this piece needs to be as fine finished as possible with absolutely precision straight cuts.

I use my jigsaw all the time, but if there is a better method/technique I am all ears.

Guys,

I have a need to cut a L-shaped piece of formica sheet. Cutting the outside edges of the piece/sheet = easy and straightforward. However, it's that inside corner that I am a bit flummoxed with. How does one get as close to 90 degrees without damaging the piece? Any thoughts on techniques (and equipment) to get this accomplished?

TIA

You don't say what saw you are using if you are . if it is a circular saw blade then cut up to your line on one side and finish it off with a hand held saw for the other. Another way is take a look at Japanese pull saws . Not thick , and can get up to 26 teeth per inch