How To Form Formica Countertops

Sketch the countertop on a sheet of graph paper. Measure the area where you want to install the Formica countertop, and transfer the dimensions to the graph paper. Double-check each measurement before recording it to ensure it is accurate.

Measure and mark the required dimensions on a sheet of Formica. Form the marks as accurately as possible and join them with a straightedge to form straight lines.

Apply lengths of masking tape over the cutting lines you created on the Formica to keep the edges from splintering. Form straight cuts over the sheet with a fine-tooth handsaw before removing the tape. Sand the cut edges of the countertop lightly until smooth.

Cut end caps to size to match the corresponding exposed edges along the countertop. Iron the end cap over the exposed edge. Tap the end caps with a rubber mallet. Trim the edges with a fine file, if needed, so they fall flush with the countertop.

Set the range top or sink face-down over the countertop and outline its perimeter. Use a jigsaw to cut a hole 1/4 inch smaller than the outline.

Lay perpendicular adjoining mitered pieces of the countertop on a flat surface for an L- or U-shaped assembly. Apply an even layer of sealant over each mitered corner before pressing them together to form a square corner. Insert fasteners into the adjoining corner and tighten them partway. Tap misaligned or uneven edges back into alignment before tightening the fasteners completely. Allow the glue to dry according to the time specified on the label directions.

Spread epoxy or contact cement on the back of the Formica sheet and the top of the cabinet where you want to install the countertop, using a trowel or paintbrush.

Grasp one end of the Formica countertop while your assistant holds the other end. Center the Formica counter over the glued top before lowering it. Install the largest, straightest edge first, gradually applying pressure over the remaining surface so it adheres to the glue underneath.

Position a roller on one side of the Formica countertop. Roll it from one side to the other to remove trapped air bubbles.

Apply a bead of sealant around the gaps between the sink and countertop hole to prevent water damage to the surface.