corian countertop #1: How to build a corian countertop with an apron

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Blog entry by Frankie Talarico Jr. posted 03-20-2009 02:28 PM 10593 reads 1 time favorited 1 comment Add to Favorites Watch
no previous part Part 1 of corian countertop series Part 2: how to build a corian countertop: part two »

There are a few corrections on the first page and can be seen here.

This information is from an actual build of a corian countertop. This was a job for united technologies 6 restrooms with three undermount sinks each. Photos were taken along the way. I will be as clear as possible on all the steps needed to accomplish this.

We are lucky enough to have a CNC for the cutouts. Laying them out on cad is extremely cost effective. If you dont have on you can use a mock-up piece you cut from plywood first.


We have to make 6 countertops for corporate office lavartories. Three sinks each,with a high gloss finish to match existing granite.

Lets start this project.

1. First you recieve and ensure the product has no defects. If so, try to still utilize maximum product by cutting around the defects. Circling the with a magic marker helps later on so you don’t forget where it is on what piecs. On this project we had six counters to make, so it can get confusing. After all this is accomplished start laying the job specs out on a full size piece of shop ply. This will ensure you have adequete room for hardware, sinks, and anything else that can get in the way.

2. After your full size layout is in order and everything works it time for cad (or a mock-up). Laying out the project now should be easy. you already have a shop ply layout, now its just a matter of copying that info into the computer.

cnc screen

cnc machine

3. Once the cad is set you can go ahead and run another piece of ply to ensure the machine is setup properly. You dont test with the actual workpiece, that stuff is pricey and the boss wont appreciate a $700.00 error from bad math. Once a perfect model is cut move on to the next step.

4. Now you can actually cut the corian to the proper depth and width. nWe used a panel saw and we leave everything big by a 1/4”. A router will be used later to make a nice clean cut that will be much easier to sand.

5. At this point you’ll want to make some space and setup a bunch of saw horses and I-Beams. I like to lay them out in a paticular fashion like a kitchen so my workspace isn’t spread out all over the shop. When it comes to routing and sanding you won’t walk 20 miles after an 8 hour day. This is the trick of a master.

  • Set it up so the height is comfortable for you and you wont be slumped over all day. This is common practise and I shouldn’t have to explain that here.

right height is good

6. Once you start machining the tops, cut slower than recommonded. this helps with chipping out and chatter. after one top is cut, unload it place it on you worksp[ace and load the next one in the machine. Cut everything at the same time, one after another until all of the are done. When you finish, your work area will be full and ready for the next step. Not to mention the boss likes the look of orginization.

7. Now it’s time to bring the tools. Grab three routers(this is best so you don’t continually change bits and have to readjust your heights.) You’ll need big router 3 1/4 HP is fine, A medium router 2 HP, and a Trim router( yup the one for laminates).
router bits
router bits

Set up all these routers together see photos below for a visual.

three bits you’ll need are:

A: 2”H x 1”D flush cut pattern bit

B: 2”H x 1/2” flush cut pattern bit

C: a 1/4” round over bit

router bit setup

-- Live by what you believe, not what they want you to believe.

1 comment so far

View MrMark's profile


31 posts in 2799 days

#1 posted 03-20-2009 08:51 PM

you’ve got some nice toys in that shop :)

Looking forward to seeing how this process works. Thanks for posting!

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