How to Use Formica & Plywood

Formica is a brand name for a form of plastic laminate made by the Formica Corporation, based in Cincinnati, Ohio. The product, which is a mixture of melamine and other products (including mica, from which it gets its name) is used as a surface covering for kitchen and bathroom countertops. The melamine can be mixed in a way to mimic different colors and styles of counters, including marble. Formica is usually glued to a wood surface which, in most cases, is either made of plywood or particleboard. Applying Formica to plywood requires roughing up the plywood with sandpaper and adhering the laminate with glue.

Rough-grit sandpaper
Cloth rag
Yardstick
Formica laminate
Utility knife
Contact cement
Paintbrush
J-roller
Router
Router bits
Wooden dowel rods
Wood file
Wooden dowels

Instructions

- 1
  Sand the surface of the plywood where the Formica will be installed with rough-grit sandpaper, scoring the surface so that the contact cement will grip better. Wipe the surface of the wood with a damp cloth, to remove any sanding dust.
- 2
  Measure the surface of the plywood using a yardstick. Use the measurements and cut the Formica by scoring it with a utility knife against the yardstick. Allow for at least 1 inch on all sides for any finish trimming you may need to add later. Break the laminate carefully at the cut lines.
- 3
  Start off with the smaller pieces of laminate, such as the edges. Apply contact cement with a paintbrush to the underside of the Formica and the surface of the plywood. Wait until the cement has dried to the point of being tacky, then apply the Formica to the plywood.
- 4
  Use a J-roller to press down on the Formica, to press out any possible air bubbles underneath the Formica.
- 5
  Repeat Steps 3 and 4 for all remaining edge pieces of Formica.
- 6
  Brush the flat upper surfaces to be laminate with Formica with contact cement. Lay several wooden dowel rods on the plywood's surface, spaced out about a foot apiece.
- 7
  Place the Formica in the proper position on the surface. Remove the dowels one at a time, making sure that the Formica stays in the right position. Use the J-roller to press down on the surface to remove any air bubbles.
- 8
  Repeat Steps 6 and 7 for any remaining surface areas.
- 9
  Trim any excess Formica using a router equipped with a laminate bit (one with a roller on the tip).
- 10
  Use a wood file and gently file the edges of the Formica to dull the sharp edges that have formed. Wipe with a damp cloth again.

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