How do I cut Formica laminate OVER Track Ball Mounting Plate?

[Timoe]

I've never liked the look of the trackball mounting plate on a control panel.  I have recessed them in the wood, covered the gaps at the edges with putty and put a vinyl CP overlay on there.  Then I used an exacto knife to cut the thin vinyl in a circle where the ball goes.  Worked great

But what about if I want to use formica?  If I apply that over the mounting plate it will give me  a nice durable surface for my CP but how will I cut a nice circle for the track ball to fit through?

Can I route it?  DO I use a utility knife?  Has anyone tried this before that can offer advice?  Thanks again.


FYI:  My flush trim bits for my router have a little gap between the guide bearing and the blade, thats why I'm unsure about routing.  What would the bearing run against?

[Knievel]

I would make a 3" hole in a scrap piece of wood and use that as your template.
Clamp your piece of Formica onto it and plunge through it and cut the trackball opening.

If you don't have a plunge bit then just pre-drill a small hole in the Formica before you clamp it on. Then you can use the flush-trim bit you have to cut the opening.

[Timoe]

But then I have to hope I can line up that 3" hole perfectly before I make contact with the adhesive.  Is this the way?

[Knievel]

That's how I've done it. When you go to glue it on just start by lining up the trackball and press it down.

You can use wooden dowels to keep the rest of the laminate up off the CP while you do it.

[Timoe]

THANK YOU.

while you're here, is the hole actually 3"?  I mean, will I go out and buy a 3" hole saw or is it more like 3 1/8" or something?

[Knievel]

It depends on how much of the black casing (ring) around the trackball you want showing. I believe I make my hole 2 3/4" and that leaves about half the ring showing.

I have a circle cutter for my router so I can do any size of hole. If you're getting a holesaw you may be limited in your choice of sizes. I would try something just under 3", with a 3" hole I think you'll be seeing the mounting plate.