Installation Guide
What you will need to make a new
laminate countertop:
Tools (minimum requirements)
• Trim router
• 3" – 9" paint/adhesive roller with cover
(
1/8" nap)
• Flush trim router bit (carbide tips)
• 1" paint brush (china bristle) —no sponge
brushes
• File
• 1/4" dowel rods 36" long (one for every
12" of countertop)
• 3" hard rubber J-roller
• Sanding block with 80-grit sandpaper
Optional tools
• Circular saw with fine tooth carbide blade
•
Scoring knife
• Laminate scissors
Recommended substrates
5/8" or 3/4" thickness
• Particle board
• Medium density fiberboard (MDF)
• Plywood with one “A” face
Application Instructions
Here are step-by-step directions. Read
carefully before beginning your project.
If you have questions please contact the
Wilsonart hotline at 800-433-3222.
Make sure the W
ilsonart
®
Laminate and the
surface you are covering are clean, dry and
smooth. Do not laminate over paint, varnish
or old covering.
Cutting your laminate
On the lam
inate sheet, mark dimensions
1/2" larger than the size of the surface to be
covered (substrate) to allow for trimming after
bonding. Place a strip of masking tape over
the cut line to prevent chipping. Mark the
line on the tape and cut through tape and
laminate at the same time when using a
scoring knife
(see drawing A). When using a
circular saw, cutting from the bottom side of
the laminate will eliminate chipping of the
decorative surface. Use a
router from the top
or bottom of the laminate when cutting.
Use the remaining material to cut strips for the
edges in the same manner as stated above.
Using WA800 Aerosol or a 1" brush with
WA600, apply adhesive to the backside of the
l
aminate edge strips and double coat the edge of
the substrate
(see drawing B). Do not apply adhesive
to top surface at this time. Allow adhesive to dry
*
.
Important! Once the adhesive is ready to bond,
i
f any contact is made between the backside of
the laminate and the edge of the substrate, they
will bond immediately
.
Be very careful to align each laminate
piece with the substrate prior to the
surfaces touching. Starting at one end of the
edge, start applying the edge strip with excess
laminate extending above the top side of the
counter. Use a hard rubber J-roller to apply
uniform pressure along the entire edge strip
(see drawing C).
Using the laminate trimmer/router, trim off
the excess laminate protruding above the
s
ubstrate surface
(
see drawing D)
. Areas that cannot
be
routed may be filed smooth. When filing never drag
a file out toward the decorative surface of the laminate.
Doing so can result in chipping of the color/pattern.
Spread the adhesive on the substrate
using your adhesive roller
(see drawing E). Tw o
t
hin coats on the surface are better than one
heavy coat. One hundred percent adhesive
coverage is required (each coat). Before applying
a second coat, make sure that the first coat is dry.
Allow adhesive on both components to dry
*
.
Position the dowel rods on the top surface
approximately 12" apart, perpendicular to
the front edge
(see drawing F). Position the laminate
carefully over the substrate. Starting at one end
of the counter, start removing the dowels one at
a time while holding the laminate in place.
Use a hard rubber 3" J-roller to apply
uniform pressure across the entire
countertop. Apply pressure to every inch of
the surface for a complete and lasting bond.
Route off the laminate overhangs with
the router and fl
ush trim bit. The radius
left by the routing process in any inside corner
should remain. A radius on an inside corner
(minimum 1/8") will strengthen the corner.
Use a file to remove sharp edges and sharp
outside corners.
Clean off excess adhesive with
W
ilsonart
1
21 Cleaner and a clean
white cloth (Acetone is also an option).
Note: Cutouts for sinks and cooktops may be made
with a jigsaw and a fi
ne tooth blade. Sand the
cutouts smooth with a file or sandpaper. Holes for
faucets may be made with a hole saw
.
*
T
o test the adhesive for appropriate dry time, lightly
touch the adhesive with your finger. If the adhesive
feels tacky yet does not stick to your finger, it is ready
to bond. Refer to adhesive manufacturer directions.
F
Do-It-Yourself
Countertop
Wilsonart
®
Fabrication Guide
2.
Laminating the edges
3.
1.
4.
5.
Laminating the top
6.
7.
8.
9.
10.
B
D
C
E
A
Laminate
HC0008
© 2000 Wilsonart International