How to Resurface Formica Countertops

Formica is a leading maker of laminate countertops

Formica brand laminates are the industry standard. The name Formica has become synonymous with laminate countertops. Resurfacing a laminate countertop is a fairly simple process that requires common tools and chemicals. If you do not own a belt sander, you will need to rent or borrow one to prepare your old countertop for resurfacing.

Things You'll Need

• Belt sander
• 80 grit belt
• Cardboard
• Contact cement
• Roller
• Laminate
• Circular saw
• J roller
• Router
• Flush-cut-bearing bit
• File

Instructions

1. Scratch the surface of the old Formica with the belt sander. Use a coarse 80-grit belt. This will break down the gloss of the old Formica, and prepare the surface for a fresh coat of contact cement. Make one pass over the entire top. Sand the edge of the countertop with a sanding block and 80 grit paper.

2. Cut a cardboard template to fit the countertop. Place it on the back of your new laminate and draw the outline. Cut the laminate ½ inch larger on all sides using a circular saw with a fine-tooth blade, installed backwards to minimize chipping.

3. Make an edge piece for the front edge of the countertop. Cut the piece ½ inch wider and ½ inch longer than the face of the countertop edge.

4. Roll a coat of contact cement onto the face of the countertop edge. Apply a coat to the back of the laminate you cut for the edge, as well, using a small, medium nap paint roller. Allow the contact cement to dry completely.

5. Position the laminate, glue side down, in front of the countertop edge. Press the laminate against the edge of the countertop firmly to adhere it in place. Use a J roller to press the laminate permanently into place and eliminate any air pockets that may have formed.

6. Trim the edges of the laminate with a router and flush-cut bearing bit. Adjust the height of the bit to ride below the edge of the laminate on the countertop, typically the top of the bearing will ride ¼ inch below the bottom of the base plate on the router.

7. Start the router and run it counterclockwise around the outside of the countertop edge to trim the laminate flush. Keep the router firmly against the face of the countertop edge, and move at a steady speed. Do not force the router.

8. Apply contact cement to the top of the countertop and back of the laminate piece you cut for it. Allow it to dry, and position and apply it as you did the edge piece. Trim the raw edge flush with the router. Apply beeswax to the edge of the bearing to prevent friction burns on the newly laminated countertop edge.

9. File the seam between the edge and top pieces using a mill bastard file. Tilt the file 45 degrees toward the top, and turn it so that the handle is below and slightly to the left of the tip. Run along the seam, applying easy pressure to smooth the edge. Check the edge with a thumb and continue working until the seam is completely flush, with no lip.

References

• "Making Plastic-Laminate Countertops"; Herrick Kimball; 1996
• "Laminate and Solid Surface Countertops"; Randy P. Jensen; 1998