How to Cut Formica

Steenes

Editor

posted on 13 years ago — updated on 1 second ago

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Formica is a versatile, plastic laminate that comes in a wide range of colors, textures, and finishes. Using Formica allows a homeowner to customize an area with a laminate that is durable and easy to clean. Learning how to cut Formica correctly can save a lot of wasted time and money as sometimes the laminate will want to crack or flake. A few easy steps before actually cutting the Formica can help make your do-it-yourself job look like a professional installation job. There are 2 ways to cut Formica, either with a jigsaw or a laminate router bit. Follow the steps below to learn more about both methods.

Steps

Using a Circular Saw to Cut Formica

Purchase the size of Formica sheet that fits best for your project. Formica sheets are between 1/16 and 1/32 of an inch (.15 and .08 cm) thick. Sheets can be 3, 4, and 5 feet (.9, 1.22, and 1.52 m) wide and 8, 10, and 12 feet (2.44, 3.05, 3.66 m) long. The smallest sheet available is generally a 3x8 feet (.9x2.44 m); however, some home improvement stores offer scrap bins if your project is small.

Measure the area you wish to laminate with a tape measure.

Mark the cutting line on the Formica with a pen or pencil.

Place masking tape on the cutting line. Use extra layers of tape at the edge of the Formica where the saw will first start the cut. If the line is not visible through the tape, remeasure and remark on top of the masking tape.

Lay the Formica on a flat, rigid surface. You can use a scrap piece of plywood or OSB as a table to cut Formica. The surface you use will probably be scored by the saws, so be sure that what you are using is safe to cut on and can get damaged. Cement would not be a good surface to cut on.

Use a circular saw or laminate shears to cut the Formica into large pieces. Do not try to cut a curve with a circular saw. Cut out the shape's form, and leave the trimming for a finer saw and corners for a saw with a some flexibility.

Install the Formica onto the countertop or other location.

Use a jigsaw with a fine blade to trim the Formica and make any rounded cuts. You can also use a trim router to finish edges if you’d like.

Use a belt sander with a grit of 100 to smooth the edges. Belt sanders can be heavy to operate, and you may choose to sand the edges by hand or with a small metal file.