How do I Remove a Particle Board Layer and Install Laminate?

Plastic laminate replacing particle board will need a substrate to attach to.

Particle board is a common, but highly unstable, wood composite material. As long as it is completely sealed from moisture, and protected from impact, it can be used as a filler in some building projects. Unfortunately it gets used in cabinets and under countertops frequently. To replace a countertop with laminate, you will need to first replace the particle board with a more stable substrate. Plywood works best and is much more moisture resistant than its compressed-sawdust cousin, particle board.

Things You'll Need

• Tape measure
• Pry bar
• Hammer
• Plywood
• Circular or jig saw
• Plastic laminate
• Contact cement
• Construction adhesive
• J-roller

Instructions

1. Measure the height and width of the particle board you plan to replace, before beginning removal procedures. Take in to account any other important dimensions, such as cut out sections or holes. If possible, keep the particle board intact and use it as a template for marking the replacement piece.

2. Pry around the edges of the particle board with a flat pry-bar and hammer to loosen it from its fasteners. Work for a little movement in each section, forcing the board will lead to it breaking. Once the edges are loose, work a larger pry bar behind and work around again until the panel is completely loose. Lift it from its position and place it on top of a sheet of plywood the same thickness as your particle board, which can range from 1/2 inch to 1 1/2 inches. Mark the outline onto the plywood.

3. Cut out the plywood replacement piece with a circular saw or jigsaw, working along the inside of the line to allow for the tracing. This will give you a slightly smaller piece, that should be the same dimensions as the original.

4. Use the plywood as a template, lay it on the back of your laminate and mark the outline onto the laminate. Make sure to place the face that will be out against the laminate to get the same shape and not a mirror-image of the panel. Cut the outline from the laminate with a circular saw with a fine-tooth blade that has been installed with the teeth reversed to minimize chipping. To install a blade in reverse,remove the blade, flip it over, and reinstall.

5. Examine the area that held the old panel. If there are available frame members or other suitable sturdy surfaces, nail the new panel in place. If not, apply a bead of construction adhesive to the back edge of the plywood. Position the panel in the opening and nail it in place. Or tap around the edge with a rubber mallet to adhere the construction adhesive.

6. Apply a coat of contact cement to the face of the plywood and to the back of the laminate. Allow it dry for 30 minutes to achieve maximum tack.

7. Position the laminate squarely in front of the plywood panel, centered with its top edge lined up with the plywood. Press the top edge carefully against the plywood working to keep the edges perfectly aligned. Work your way down the piece pressing it firmly into position. Use a J-roller to press the laminate permanently into place.

References

• Hardware Store: How to Install Plastic Laminate Countertops
• "Cabinets & Countertops: Builder-tested, Code Approved"; Taunton Press; 2006