How to Build Laminate Counter Tops

Working it Out

Adding a personal touch to the kitchen is a popular home improvement project. One way to do this is to build your own laminate countertops. While this requires a certain skill level, if you are familiar with power tools such as a table saw and router, this is a doable project. Remember to take every precaution to guard against injury or ruining the material purchased. The example below is 26 inches wide and 96 inches long, has a sink cutout.

Things You'll Need

• 1 sheet of 3/4-inch plywood (at least good on one side)
• Laminate
• Table saw
• Framing square
• Circular saw
• Jig saw
• Wood glue
• 3D box nails
• Hammer
• Contact cement
• Paint roller
• Paint brush
• Variable speed drill
• 3/4-inch drill bit

Instructions

Cutting the Materail

1. Set the fence of the table saw on 26 inches. Rip the length of the 3/4-plywood to give yourself a piece that measures 26 by 96 inches. This is the deck of the counter top.

2. Set the fence of the table saw to 2 inches, and rip three pieces from the leftover plywood in Step 1. These will become the buildup around the perimeter of the countertop.

3. Set the fence of the table saw to 28 inches. Rip one piece of the laminate material. Be certain that it is 2 inches wider and longer that the 26-by-96 inch piece of plywood cut in Step 1.

4. Set the fence of the table saw to 3 inches, and rip two pieces of laminate to cover one long edge and one short edge. Set all the laminate aside for now.

Sink Cutout and Buildup

1. Measure out from the corner of the wall to where the center of the sink will be. Measure from the end of the plywood, and make a mark that represents the center of the sink. From that mark, draw the pattern for the sink. A standard cutout for a double sink is 22 by 32 inches and has rounded corners. If your sink is different, follow the manufacturer's instructions.

2. Cut the straight lines with the circular saw by holding the blade over the line and lowering it through the countertop. Do this for all four of the straight lines. Drive two nails at an angle into the 22-inch sides that are part of the cutout. This will hold the cutout in place while rounding the corners. Cut the rounded corners with the jigsaw.

3. Measure and cut two pieces of plywood--20 inches in length--from the 3-inch strips. Apply glue to the perimeter of the 26-by-96 inch piece of plywood about 1 1/2 inches from the edge. Secure the two 96-inch strips with the box nails followed by the two 20-inch pieces.

4. Turn the countertop over and sand the edges with the sanding block. Use 100-grit sandpaper. Sand them until they are relatively smooth.

Laying the Laminate

1. Place the two 3-inch-wide strips of laminate on the plywood countertop. Measure and cut one piece to 28 inches and the other to 98 inches. Turn them so the backside is facing up.

2. Apply contact cement to the front and one side edge of the plywood. Allow this to dry. Apply a second coat to the plywood and one coat on the backside of the laminate strips.

3. Place the longest strip on the longest edge, allowing some of it to hang over the top and the bottom of the plywood top. Butt the square end of the short piece into the laminate hanging past the end of the long edge. Be certain they are secure before routing off the excess.

4. Cut the excess of the edging with a router and a laminate-cutting bit. Sand the top and bottom edge of the laminate with a sanding block and 100-grit sandpaper.

5. Clean the top surface of the countertop of all debris. Apply a coat of contact cement to the plywood and let it dry. Apply a second coat and a first coat on the back of the laminate.

6. Place the dowels on the countertop when the contact cement is tacky. Place the laminate on the dowels, and start pulling the dowels out from under the laminate. Be certain the laminate makes contact and is smooth.

7. Cut the excess with the router and the laminate-cutting bit. Drill a hole in the sink cutout so the router can cut the laminate from that area. Knock off the sharp edges with a file.

Tips & Warnings

• Clean up excess glue with lacquer thinner and a soft cloth. Be certain to check all the edges of the laminate, and file all of them that are sharp.

• Always wear safety glasses when cutting wood or laminate. Do not apply contact cement in a poorly ventilated area. Do not smoke or strike a match in the vicinity of the contact cement.

Resources

• Replacing a Laminate Countertop
• How to Laminate a Countertop