How to Make a Formica Countertop
A Formica countertop is made by laying down Formica sheets on your existing countertop. Formica is versatile enough to be used not only on kitchen countertops but also as a laying material on bathroom and kitchen cabinets. Formica sheets are available in various textures, patterns and color and are readily available for purchase. Follow the instructions below to create your own Formica countertop.
Step 1 - Cutting a Particleboard to Countertop Measurement
Cut a sheet of particleboard to the countertop’s measurement using a circular saw. Leave a 1-inch allowance for the Formica edges that does touch the wall. Cut strips of particleboard measuring 4 inches wide and with the length of the edges. Glue the strips to the underside of the particleboard along the borders, and attach 1¼-inch wood screws. Sand the edges for smoother effect.
Step 2 - Laying the Formica Laminate
Lay the Formica flat on an even surface then mark the measurements of the countertop on it. Leave an allowance of ½-inch at the edges of each side. Place a 2x4-inch lumber sheet underneath the laminate aligning the tops. Fasten the sheet tightly to the lumber.
Step 3 - Countertop Sidings
With a trim router, cut the sheet along the lines. Cut side strips about 1½ inches in width and 1 inch in length for the sidings of the countertop.
Step 4 - Applying Contact Cement
Brush contact cement onto the short side of the laminate and to the plywood end. Allow the materials to fully dry. If you like, add a second coating of contact cement.
Step 5 - Applying the Laminate
Start putting in the laminate to the plywood, and smooth the area with your hands. You can use a J-roller to firmly press the materials and create a smoother finish. Trim off any excess Formica laminate. Smooth out the edges and the particleboard with a file.
Step 6 - Applying Contact Cement and Adhesive
Apply contact cement to the back of the top piece of the laminate with the use of a roller. Put adhesive on the plywood. Allow the contact cement and the adhesive to completely dry.
Step 7- Connecting the Laminate to the Plywood
Apply dowels on the plywood top at 12-inch intervals. Position the Formica laminate with the right side up over the dowels. Have the laminate and the plywood lined up with the laminate not in contact with the plywood. Take out the center dowel, and then push the laminate downwards. Finish taking out the dowels and press firm the materials. If there is any excess on the edges, trim it off.
Step 8 - Creating the Backsplash
Create a backsplash for the laminate by cutting a plywood piece 5½ inches in width and the length of the countertop. Process the backsplash attachment in the same way as the countertop. The bottom part of the backsplash front should be caulked and aligned to the back of the countertop. Screw them securely. Install the countertop.