Laminate countertop joint
With just a router there are a couple of ways to cut the HPL to fit. If you buy a laminate file it will sure make things easier for you. What type of router cutter do you have? If we knew that we could suggest a way to cut the HPL straight then file to fit. If you are real close with your fit you can take the HPL file lay it flat against the edge of the HPL so all of the file is making contact with the edge of the plastic. You can then file the edge straight to fit better.
If your router bit has an area that will ride against something as a guide you can clamp the HPL to a top of something sturdy, then use something that is dead straight to let the pilot of the cutter ride against it.
If you have a belt sander you can draw a straight line across the end then use the belt sander to sand back to that line then finish dressing the joint with the file. If you do use your belt sander, clamp the HPL down to a table or something you can let the HPL over hang by a 1.2 inch or so, hold the belt sander at a 90° angle so you are sanding from the front of the HPL to the backside. Watch very close as you sand closer to the line you want to be as close as possible but not cut past the line. Dress with the HPL file. Be very careful, HPL is sharp as a razor believe me.
I wish you were closer you could use my seaming router to make the joint.
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Last edited by BigJim; 05-20-2012 at 08:11 PM.