Author Topic: Best way to cut corian?  (Read 4192 times)

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Offline Alex

  • Posts: 6636
Best way to cut corian?
« on: February 16, 2020, 09:58 AM »
Hi guys, I need to cut corian to size and make a few holes in it to mount a toilet. I have not worked with this material before so to avoid any mistakes I'd like to fall back on your expertise.

Unfortunately I am a bit limited in my tools at the moment as I am 750 km from home to redecorate an apartment in Germany, high up in the mountains near the Swiss border.

What I have with me is the TS55, the router, jigsaw, and drill with hole saws.

What would be the best way to do this? Is this sturdy material, or easy to mess up?

BTW, my view now:


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Offline Bert Vanderveen

  • Posts: 671
Re: Best way to cut corian?
« Reply #1 on: February 16, 2020, 10:57 AM »
Anything Tungsten will do the trick. To make sure you get nice edges I would cut oversized and clean up with a router (as far as stuff is in sight). To glue Corian onto anything use acrylic, preferably in the same colour.

If you can, use the special saw blade FS sells. Its geometry is better for the intended use.
Cheers, Bert Vanderveen

TS55 · TS55R · OF1010 · DF500 Mk2 · MFT/3 + TSB1-MW 1000 + VL + CMS TS55 + CMS PS300 + LA-CS 70/CMS · CTL Midi · RTS400 EQ · 2 x CXS Li 1,5 · T15+3 Li 4,2 · TI15 Impact Li 4,2 · Centrotec Sets 2008 + 2015 · PSB300 · LR32-SYS · RO150 · Kapex KS120 · 2 x MFK700 · RO90 · OFK700 · BS75 · OFK500 · OF2200 · CMS-GE · Vecturo 18 Li · TID 18 · TKS 80 EBS-Set · … | Mirka 1230L P&C | Hammer A3 31 Silent Power · Hammer N4400 · Hammer HS950 | TaigaTools VacPods Pro Set
Wishlist: ETS EC 125 w 150 pad, DTS

Offline Alex

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Re: Best way to cut corian?
« Reply #2 on: February 16, 2020, 11:13 AM »
Glue with acrylic, what's that for glue?

I do have the special blade, thought that one might be best.

Offline waho6o9

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Re: Best way to cut corian?
« Reply #3 on: February 16, 2020, 11:22 AM »
The fitters that cut our counter tops said to use tungsten carbide.

Offline tjbnwi

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Re: Best way to cut corian?
« Reply #4 on: February 16, 2020, 11:29 AM »
I use the blade Festool sells for solid surfaces.

As noted above a slight over size cut and router clean up is good practice. You can cut to size if the edge detil will remove any defects.

If you're doing a build up use the recommened adhesive. You'll need the proper gun for the adhesive.

The stuff gets slick as snot, use spring clamps and back up blocks. Hot glue the blocks on, denatured alcohol disolves the hot glue for removal.

With build up, always over cut and router trim back.

I use drywall shim to make the templates.

Hole drilling, I prefer a sharp toothed hole saw over an abrasive hole saw. Do not use an auger or paddle bit.

Tom

Offline tjbnwi

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Re: Best way to cut corian?
« Reply #5 on: February 16, 2020, 11:33 AM »
Glue with acrylic, what's that for glue?

I do have the special blade, thought that one might be best.

If you need to build up the edge to make the top appear thicker than the sheet material. Pretty common practice.

Scuff sand where you need to glue, wash clean with denatured alcohol.

The gun and adhiesive tube is visible in this picture.

Tom

Offline tjbnwi

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Re: Best way to cut corian?
« Reply #6 on: February 16, 2020, 11:33 AM »
You may also need to buff/polish the top.

Tom

Offline Alex

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Re: Best way to cut corian?
« Reply #7 on: February 16, 2020, 01:07 PM »
Thank you for answers. I work for an interior decorator and he slipped this in at the last moment when I was already loading the van and didn't have time to research this and properly prepare.

I have the standard blade and the special laminate blade with me, so I'll cut it oversize and then trim with the router.

I do not have any special glue with me like the 2 part glue you show. I only have standard construction glue with me, called 4tecx High Tack and considered as an excellent general purpose glue for a wide range of materials. Would that suffice or do you really need special glue?

Offline Distinctive Interiors

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Re: Best way to cut corian?
« Reply #8 on: February 16, 2020, 01:20 PM »
I do a fair bit of Corian fabrication and I would strongly advise you to only use the 2 pack adhesive as mentioned by the other posters.

I have heard of people using CA glue with success on very small pieces, but if you are glueing edges to create what appear to be thicker panels, you will need the proper adhesive.
Also, to ensure the manufacturers warranty would be valid, you have to use the correct adhesive.....Sorry Alex....!

Offline tjbnwi

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Re: Best way to cut corian?
« Reply #9 on: February 16, 2020, 04:28 PM »
You have to use the proper adhesive. There is nothing that sticks well to solid surface material.

Any chance your there long enough to order the product and gun to assemble later in the week?

Make sure you order the proper color, otherwise you may have a visible seam line along the edge.

Nice looking area you'll be working in by the way.

Tom

Offline Michael Kellough

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Re: Best way to cut corian?
« Reply #10 on: February 16, 2020, 05:14 PM »
Be especially careful protecting your lungs from the dust.
Cutting synthetic “stone” composites produces about four times as much silica dust as cutting granite.

Offline Alex

  • Posts: 6636
Re: Best way to cut corian?
« Reply #11 on: February 17, 2020, 02:19 AM »
Thank you all for your answers, I will track down the proper glue, my designer is in contact with his supplier to have it send out to me. I won't be needing it until next week.

I do not need to polish it, designer wants the matte look, apparently that's totally the thing now over here.

And I'll wear my respirator when cutting it.  [smile]

Offline Distinctive Interiors

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Re: Best way to cut corian?
« Reply #12 on: February 17, 2020, 04:02 AM »
Be especially careful protecting your lungs from the dust.
Cutting synthetic “stone” composites produces about four times as much silica dust as cutting granite.

Hi Michael,

Can you post a link that goes into more detail regarding this please....?

It would be much appreciated.

Tim.

Offline Cheese

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Re: Best way to cut corian?
« Reply #13 on: February 17, 2020, 09:47 AM »
I do not need to polish it, designer wants the matte look, apparently that's totally the thing now over here.

Alex, what grit paper will you use for the matte finish?

Offline Bert Vanderveen

  • Posts: 671
Re: Best way to cut corian?
« Reply #14 on: February 17, 2020, 09:53 AM »
Glue with acrylic, what's that for glue?

I do have the special blade, thought that one might be best.

To 'glue' Corian and such onto different substrates (for instance plywood) my go-to furniture guy uses "Simson Professional BSR 50-10 Acryl Universeel (wit)", and so do I : ) . Dots or beads, not full area's.
Cheers, Bert Vanderveen

TS55 · TS55R · OF1010 · DF500 Mk2 · MFT/3 + TSB1-MW 1000 + VL + CMS TS55 + CMS PS300 + LA-CS 70/CMS · CTL Midi · RTS400 EQ · 2 x CXS Li 1,5 · T15+3 Li 4,2 · TI15 Impact Li 4,2 · Centrotec Sets 2008 + 2015 · PSB300 · LR32-SYS · RO150 · Kapex KS120 · 2 x MFK700 · RO90 · OFK700 · BS75 · OFK500 · OF2200 · CMS-GE · Vecturo 18 Li · TID 18 · TKS 80 EBS-Set · … | Mirka 1230L P&C | Hammer A3 31 Silent Power · Hammer N4400 · Hammer HS950 | TaigaTools VacPods Pro Set
Wishlist: ETS EC 125 w 150 pad, DTS

Offline Bert Vanderveen

  • Posts: 671
Re: Best way to cut corian?
« Reply #15 on: February 17, 2020, 10:41 AM »
I do not need to polish it, designer wants the matte look, apparently that's totally the thing now over here.

Alex, what grit paper will you use for the matte finish?

Usually Scotch Brite is used. The finer the higher the gloss.
Cheers, Bert Vanderveen

TS55 · TS55R · OF1010 · DF500 Mk2 · MFT/3 + TSB1-MW 1000 + VL + CMS TS55 + CMS PS300 + LA-CS 70/CMS · CTL Midi · RTS400 EQ · 2 x CXS Li 1,5 · T15+3 Li 4,2 · TI15 Impact Li 4,2 · Centrotec Sets 2008 + 2015 · PSB300 · LR32-SYS · RO150 · Kapex KS120 · 2 x MFK700 · RO90 · OFK700 · BS75 · OFK500 · OF2200 · CMS-GE · Vecturo 18 Li · TID 18 · TKS 80 EBS-Set · … | Mirka 1230L P&C | Hammer A3 31 Silent Power · Hammer N4400 · Hammer HS950 | TaigaTools VacPods Pro Set
Wishlist: ETS EC 125 w 150 pad, DTS

Offline Cheese

  • Posts: 7521
Re: Best way to cut corian?
« Reply #16 on: February 17, 2020, 10:43 AM »
Usually Scotch Brite is used. The finer the higher the gloss.

So Vlies on a sander?

Offline Distinctive Interiors

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Re: Best way to cut corian?
« Reply #17 on: February 17, 2020, 11:09 AM »
Matt Finish on Corian, as recommended by them, is up to 320 with Mirka Abranet ....but I use Festool Vlies.

Offline tjbnwi

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Re: Best way to cut corian?
« Reply #18 on: February 17, 2020, 11:15 AM »
Check with the supplier for the recommended adhesive to mount the top to the cabinet. I use Sil-A-Bond.

Also if the top of the cabinet is filled solid, cut a lot of it out. The wood expands and contracts differently than the solid surface.

Tom

Offline Michael Kellough

  • Posts: 4828
Re: Best way to cut corian?
« Reply #19 on: February 17, 2020, 03:19 PM »
Be especially careful protecting your lungs from the dust.
Cutting synthetic “stone” composites produces about four times as much silica dust as cutting granite.

Hi Michael,

Can you post a link that goes into more detail regarding this please....?

It would be much appreciated.

Tim.

Looks like I’m mistaken.
Striking out looking for what I thought I heard or read about it having four times as much silica.

Everything I see comparing synthetic stone to granite says it only has twice as much silica as granite.

“The countertops are made from processed quartz, a material containing silica levels as high as 90 percent, or twice the amount found in granite.”

This place says it’s up to 95% silica but they sell dust collection systems.

Offline Alex

  • Posts: 6636
Re: Best way to cut corian?
« Reply #20 on: February 17, 2020, 04:13 PM »
I do not need to polish it, designer wants the matte look, apparently that's totally the thing now over here.

Alex, what grit paper will you use for the matte finish?

I don't know, don't ask me such difficult questions!  [smile]

It is the first time I'm working with this stuff. I didn"t even know you can sand it.

I asked my designer to ask his supplier and the answer he got back was that you can use any good construction glue to glue corian on other materials, he specifically mentioned the 4tecx glue I have. But you have to use the 2 part glue Tom mentioned if you want to glue 2 plates of corian together, and then you can sand it to make the connection seamless. Looks like I'll have to do both.

Offline Dan Rush

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  • Trim carpenter
Re: Best way to cut corian?
« Reply #21 on: February 17, 2020, 06:32 PM »
Festool USA published this guide years ago. (Sorry for the poor picture) You might find it on their site somewhere.

Offline tjbnwi

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Re: Best way to cut corian?
« Reply #22 on: February 17, 2020, 09:22 PM »
I do not need to polish it, designer wants the matte look, apparently that's totally the thing now over here.

Alex, what grit paper will you use for the matte finish?

I don't know, don't ask me such difficult questions!  [smile]

It is the first time I'm working with this stuff. I didn"t even know you can sand it.

I asked my designer to ask his supplier and the answer he got back was that you can use any good construction glue to glue corian on other materials, he specifically mentioned the 4tecx glue I have. But you have to use the 2 part glue Tom mentioned if you want to glue 2 plates of corian together, and then you can sand it to make the connection seamless. Looks like I'll have to do both.

I'm going to explain an earlier statement I made. The reason you should not place solid surface matierial on a full top cabinet is they move very differently. Solid surface moves with changes in temperature, wood moves with changes in moisture. You don't want the products fighting with each other.

Never use an adhesive that hardens for the install, it must stay flexible, why I use Sil Bond. A veryslight gap to the wall is acceptable. The tops move.

A few pointers on using the two part adhesive;

Get extra mixing tips---at least six more, that should give you 8 tips. I buy them a box of 50 at a time.

Make sure you get the gun for the 2 part.

Place the tube in the gun, it will only go in one way.

Remove the caps from the tubes, do not install the mixing tube yet, hold the open end of the tube about 1" above scrap card board, squeeze the trigger until you get material to just expose.

Install the mixing tube, again over the cardboard squeeze the trigger until you get a dollop of adhesive on cardboard about 1" in diameter and 1/8" high. This gets the tube "primed".

You must do the above every time you need to apply adhesive.

Run a bead about 1/4" from the edges, run a squiggle between them.

Once done applying install the build up, next step, remove mixing tube, reinstall caps.

A few on doing the work;

MAKE A TEMPLATE

Make sure you glue on the back up blocks. Any other way is a lesson in frustration.

Clamp the build up where you want it, glue on the blocks with just a corner touching the build up.

Install one piece of build up at a time.

Practice with how you put the clamps on, you can move the build up around with the clamps when the adhesive is wet.

If there is a corner that needs build up, use a lap joint.

DO NOT wipe off any squeeze out, sand it off latter.

You'll need build up along the unseen sides. I use 15/16" strips of MRMDF (thickness assumes 2 pieces of build up stacked), you can use scrap solid surface.

I flush everything up using 2200's with special bits in them, then I sand.

Try to do any polishing before installing.

I'm sure I forgot something---good luck.

The one with the octagon weighed over 600 pounds. There is a staircase in a location where you can see the bottom of the top. It is kinda hollow, but appears solid. Forgot, the leg you see with the outlet/receptacle is hollow solid surface.

Tom



 
« Last Edit: February 17, 2020, 09:26 PM by tjbnwi »

Offline Alex

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Re: Best way to cut corian?
« Reply #23 on: February 18, 2020, 12:52 AM »
Wow, so much info, I knew you guys wouldn't let me down.

Thanks Dan for that resource article, that's gonna come in handy.

And thanks Tom for that very detailed explanation, I'm sure that will save me some frustration indeed.

Looks like working with corian is a whole trade by itself, my head's still buzzing from learning how to plaster the last 3 months, now I'll have to find a corner somewhere to stuff this information.

Tom, I won't be glueing this onto wood, but on a built-in water reservoir for a toilet like this:


« Last Edit: February 18, 2020, 12:54 AM by Alex »

Offline Distinctive Interiors

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Re: Best way to cut corian?
« Reply #24 on: February 18, 2020, 02:45 AM »
One more point to add to Tom's detailed info.....

Wherever you make a cutout in the Corian, dont leave any  sharp internal corners. Always leave a small radius in the corners. For example, the cutout for that rectangular Flush Valve, I would make a template jig and cut it out with a router.

Good Luck with it Alex!
« Last Edit: February 18, 2020, 03:32 AM by Distinctive Interiors »

Offline kcufstoidi

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Re: Best way to cut corian?
« Reply #25 on: February 18, 2020, 07:10 AM »
One addition to Tom's detailed description is you only have about 5 minutes working time before the epoxy starts hardening both in the mixing tube and your project. Thats why the extra mixing tubes are recommended. A couple of dozen 2" spring clamps are your friend for small projects, I have 100+ for corian countertop glueups.

Offline Distinctive Interiors

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Re: Best way to cut corian?
« Reply #26 on: February 18, 2020, 08:51 AM »
One addition to Tom's detailed description is you only have about 5 minutes working time before the epoxy starts hardening both in the mixing tube and your project. Thats why the extra mixing tubes are recommended. A couple of dozen 2" spring clamps are your friend for small projects, I have 100+ for corian countertop glueups.

 [eek]  Blimey!,....The weather must be a lot hotter in Canada than I have been led to believe!

Even in the height of Summer over this side of the Pond, you will get 15 to 20 mins before the adhesive sets hard.

In February in the UK, in an unheated workshop, its closer to 45 mins......

The glue nozzles are a one time use, but you do normally get 2 with each tube of 2 part adhesive....
« Last Edit: February 18, 2020, 08:54 AM by Distinctive Interiors »

Offline tjbnwi

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Re: Best way to cut corian?
« Reply #27 on: February 18, 2020, 09:04 AM »
Told you there were little things I forgot. Thanks for covering them.

One more thing----scuff sand where you're going to apply the solid surface adhesive, 150-180 grit will work.

I'd still use Sil-Bond to mount the cover to that frame.

Clamping the build up for the piece that will go on that frame, I'd have about 150 clamps on it. I have ~600 2" spring clamps and run out at times.

Alex, go back and look at the pictures I my previous posts, they will make this all much clearer.

Template, template, template......

Tom

 

Offline tjbnwi

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Re: Best way to cut corian?
« Reply #28 on: February 18, 2020, 09:06 AM »
One addition to Tom's detailed description is you only have about 5 minutes working time before the epoxy starts hardening both in the mixing tube and your project. Thats why the extra mixing tubes are recommended. A couple of dozen 2" spring clamps are your friend for small projects, I have 100+ for corian countertop glueups.

 [eek]  Blimey!,....The weather must be a lot hotter in Canada than I have been led to believe!

Even in the height of Summer over this side of the Pond, you will get 15 to 20 mins before the adhesive sets hard.

In February in the UK, in an unheated workshop, its closer to 45 mins......

The glue nozzles are a one time use, but you do normally get 2 with each tube of 2 part adhesive....

10 minutes tops here. Maybe we get the "good stuff". Causes more dead brain cells but hey, why not [scared]

Tom

Offline kcufstoidi

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Re: Best way to cut corian?
« Reply #29 on: February 18, 2020, 06:16 PM »
One addition to Tom's detailed description is you only have about 5 minutes working time before the epoxy starts hardening both in the mixing tube and your project. Thats why the extra mixing tubes are recommended. A couple of dozen 2" spring clamps are your friend for small projects, I have 100+ for corian countertop glueups.

 [eek]  Blimey!,....The weather must be a lot hotter in Canada than I have been led to believe!

Even in the height of Summer over this side of the Pond, you will get 15 to 20 mins before the adhesive sets hard.

In February in the UK, in an unheated workshop, its closer to 45 mins......

The glue nozzles are a one time use, but you do normally get 2 with each tube of 2 part adhesive....

Depends on where you live, this area can see highs close 100F and lows to -25F. I also never work in an unheated shop in Winter or an uncooled shop in Summer. I was also lead to believe all you got was rain and fog, LOL.
 
I would also assume being on a different continent you might have a different epoxy supplier hence the difference. So maybe when Alex does his glueup he can pass on his experience, like Tom and I have passed on ours.

 A very simple glueup might take 2 tips from my experience, on some larger jobs I've 8 or 10 tips.
« Last Edit: February 18, 2020, 06:29 PM by kcufstoidi »