Corian is a brand name used for a line of solid-surface countertops made from plastic resin and crushed minerals. Once in place, the counters last for decades with only minimal maintenance necessary to retain their appearance. Before placement, however, you must cut the counters to fit, as well as glue multiple counters together so you can cover any angular countertops present. Cutting Corian uses much the same cutting process as that used with wood, though some adjustment is necessary due to Corian's tendency to splinter during the cutting process. Gluing the material follows the general woodworking process as well, only with epoxy as the binder instead of wood glue.
Instructions
1. Place a mark on the edges of the Corian countertop where you wish to cut the material with a pencil.
2. Set the counter face down over a pair of sawhorses. Place a piece of masking tape across the counter, centered at the penciled marks, then place a line down the center of the tape, connecting the pencil marks across the rear of the counter. The tape prevents the counter from splintering as you cut it, with the penciled line serving as a guide for the saw blade.
3. Attach a fine-tooth carbide blade to a circular saw. Place the saw onto the counter with the blade along the edge. Start the saw then cut through the counter, following the guideline with the blade until you've cut completely through the countertop. Turn off the saw once you've completed the cut.
4. Use a belt sander with 50-grit sandpaper to smooth the edge of the Corian counter where you made the cut. Remove the remaining masking tape.
5. Position the countertops needing joining onto the base cabinets. Lay a bead of epoxy along one side of a seam support strip, then press the strip to the bottom edge of one of the countertops so the other half of the strip sticks out.
6. Lay a second bead of epoxy onto the other half of the seam support strip. Run a bead of epoxy along the connecting edge of one of the counters as well. Place the second countertop onto the extended half of the seam support strip and then push the two pieces together, taking care to match the edges of the countertop to create a smooth transition from one to the other.
7. Place clamps onto the plastic clamping blocks on the tops of the countertops. The blocks are parallel to one another. Tighten the clamps to pull the counters tightly together. Allow the epoxy to dry completely. Consult the epoxy manufacturer's instructions for drying times.
8. Unclamp the two pieces when dry, then remove the plastic blocks from the countertops by using a hammer to knock them free with a blow to the side. Sand the seam between the two counters with a power sander using 100-grit sandpaper to remove excess epoxy, then switching to 200-grit sandpaper to sand the surface between the two counters level and smooth. Wipe any sanding residue from the countertops with a tack cloth.
Tags: bead epoxy, seam support, seam support strip, support strip, bead epoxy along, between counters, counters well
