I have made formica counters many years ago and can’t remember exactly how I made them. What circular saw blade do you use? After you glue the top on what router bit do you use to trim the edge? Then after the sides are glued on what router bit do you use to trim top and bottom? Thanks
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I've gotten fairly good results using a quality general purpose blade. You can tape over the cut line w/ masking tape to help prevent chip out. If you don't mind the expense of a new blade, get one of the blades designed for melamine & veneers, etc. & use the tape.
On the router side, they sell sets of bits for laminates. One to do the straight flush cut & one to add the bevel/chamfer on the top edge. If you're edging with wood, T-mould or something else, all you need is the bearing guided flush cutting bit. If you don't want to buy a bit to do the chamfer, you can get by with just a flush cutting bit & ease the edge of the top with a file. A lot of people will either use Crisco or Vaseline around the edge on which the bearing rides as a safeguard to prevent burning in the case of a bearing seizure or as the primary lubricant if they're using the bearingless pilot guided solid carbide bits.
I use a single tooth carbide cutter to score the back side and then snap off. NO SAW BLADE. I use a file (followed by a sanding block) to trim and bevel the edge... NO ROUTER BIT. It takes a bit longer to get it done this way but actually saves a whole lot as you only have to do it once and use one set of materials.
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