Installation Guide for Solid Surface Countertops
Installing Solid Surface Countertops
Most homeowners are under the impression that solid surface countertops are beyond their abilities and that many specialty tools are necessary. The following “How-To” article dispels these assumptions. Making precise measurements and taking your time before cutting the material will facilitate getting professional results. Solid surface material is available to home owners through the website SolidSurface.Com.
Cutting the Solid Surface Material
Solid surface material is heavy so it is best to cut and shape it while it is stationary rather than trying to push it through a table saw. The following suggestions will help to accomplish the task.
Set up saw horses with a soft wooden top to them. That allows the saw to cut through the material and into the top part of the wood on the sawhorse while the material remains in place. Ensure the saw horses are level. Adjust the depth of cut on your circular saw so the blade extends about 1/8” below the countertop material. Use your safety glasses and make your cut.
Mirror cutting for seaming 2 pieces
The edges to be joined are machined at the same time which provides a perfect fit where the seam is almost invisible even before the two pieces are glued together. Use a 1/2″ shank double fluted router bit. Securely clamp the two pieces to be seamed 1/4″ to 3/8” apart so they cannot move. Securely clamp a straight edge to one side so the router can cut down the middle of the opening in one continuous movement without stopping. 
Clamping the pieces together for a mirror cut
Use a router to make the mirror cut, notice the straight edge clamped to the material to aid in making a perfectly straight cut.
Make a Straight Cut using a Circular Saw and Router.
Make a rough cut with the circular saw and leave about ¼” of material to be removed with a router as the finish straight cut.
Leave about ¼” of material to be removed with a router
Routing a Straight Edge after Cutting with a Circular Saw
Installer’s tip: for cutting the edge of a surface for later seaming ONLY USE the mirror cutting method as described above—unless you have a $30,000 panel saw or CNC machine.
