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Best way to connect melamine panels?
1UP:
Alright, I'm in the home stretch here! I finally bought the wood for my cabinet, and the last few controls, t-molding, and odds and ends. I decided to go with 3/4" black 2-sided melamine (basically pre-laminated particle board).
My question is, what is the best way to construct a sturdy cabinet at this point? Should I just pre-drill holes and screw into the ends of my melamine, or do I need cross-dowels, dadoes, or 1x2s? Should I bother gluing as well as using screws? Do I need to strip away the melamine finish if I do glue two pieces together? How can I finish the edges where the saw has chipped the black laminate?
Thanks!
ErikRuud:
Let me put it this way,
Predrilling should be mandatory.
Glueing is better than not glueing. I am not sure if stripping the melamine is necessary, but it would seem to make sense.
Screwing into 2x2 or cross dowels is better than screwing into the particle board. 2x2 would be easier than cross doweling, you would have dress up the ends of the dowels.
Dadoes in particle board are probably more work than they are worth.
I don't have any ideas for repairing the chipping. You can minimize the chipping when cutting with a circular saw by making sure that the "good side" (the side that will show) is down. On a table saw the "good side" should be up.
1UP:
--- Quote ---I don't have any ideas for repairing the chipping.
--- End quote ---
Jack:
A good way to minimize chipping is to put a couple layers of masking tape on both sides before you cut.
Steve Graffeo:
I am just a few steps ahead of you as far as completion of my cab. Let me give you a few pointers which I learned about 3/4" melamine.
Rough Cutting Parts:
1. Unless you want to purchase a specific table saw blade for cutting melamine, you can:
A - Use a blade with as many teeth as you can find and use carbide tip if possible.
B - Cut half way through the material, flip it over and cut the other side.
C - (The Way I Chose) I cut oversized pieces, then using a straight edge clamped to the material, use a router with a carbide tip straight cutter to clean it off.
Oh yeah, important: DONT USE TAPE ON THE CUT LINES. This will gum up your router bit decreasing its cutting abaility and you will end up chipping the melamine. I know pencil is nearly impossible to see on black melamine but trust me, don't use tape.
As far as T-moulding.. it is imperative you get the right slotter for the molding. Be sure it is carbide tipped..
I mention carbide for all cutting because a chromium tip bit will last all of one cut before you chuck it. Melamine is super tough stuff. It will eat your saw blades and router bits >:(.
As far as screwing the cabinet together, always pre drill. Im using drywall screws through the outside into the endgrain of an adjoing board. Also always use glue, you dont need to strip the melamine off, just use a good quality glue. (gorilla glue) As far as the screw heads on the outside, I then have small black decorative caps that tap over the screw head. Viola, no visible screws! If you want them try a place that sells panelling, they are like .02c each.
Most importantly - Be patient and take your time.. Im so totally psched to finish my cabinet I have to hold my self back from taking short cuts. The project is larger than it appears. If you want good results, dont let your emotions get the best of you! :D
Good Luck and Have Fun! ;D