Formica questions

[MrBond]

Hi all.  I'm about to start constructing my control panel that will be place on my upright cab.  (at the moment, I have a stand alone CP for my computer, but it just would'nt look right on the cab  )  Anyway, I did some thinking and I want to go with a formica top (one with a real nice black/green marble effect) to the control panel.  

I have some questions though:
1)  Where is the best/cheapest place to buy formica?  Any chance of getting a "broken" piece that would suit my small CP?

2)  How do I work with this stuff?  I've been told I need to use a router with a special bit to cut formica.

3)  Any misc. advise before I order/start (links with pics?)?

Thanks a bunch!  Cheers!  

[dhansen]

Are you in the states?  If so, Menards sells sheets in smaller sizes, I think theyre around $11 and have enough formica to do an entire control panel.

You will also need a laminate cutting bit for your router. Scotts unicade has a good tutorial on this:

http://home.austin.rr.com/shumate/unicade/cabinet.htm

Have fun!
Doug

[SNAAAKE]

Hi all.  I'm about to start constructing my control panel that will be place on my upright cab.  (at the moment, I have a stand alone CP for my computer, but it just would'nt look right on the cab  )  Anyway, I did some thinking and I want to go with a formica top (one with a real nice black/green marble effect) to the control panel.  

I have some questions though:
1)  Where is the best/cheapest place to buy formica?  Any chance of getting a "broken" piece that would suit my small CP?

2)  How do I work with this stuff?  I've been told I need to use a router with a special bit to cut formica.

3)  Any misc. advise before I order/start (links with pics?)?

Thanks a bunch!  Cheers!  

you can order online but I suggest you look around LOCALLY...here is how i got a deal..i went to this laminate place that sold heavy weight matt laminate for only 14.99 for 4x8 sheet(home depot sells exact same one for $47..OUCH ! ).

now this place also had 2 broken pieces that normally goes for $75 a sheet but they gave be 2  4x8 sheets for only $100 instead of the total being $150(seen my new cabinet lately bond?)

my the advice is to look for some place local that sells all kind of laminate and you might get a deal.

if you dont have a router then i suggest you get a cheap $10 plexi glass cutter and cut your laminate with that(my second cabinet is all laminate and i only used that $10 cutter).
Other wise Scott explains clearly how things go.

you use contact cement to apply the laminate.

If you are REALLY PICKY about the looks then you can order upto 10 samples online and see which ones you might like(this is if you are *PICKY*).
here is the place..
http://www.wilsonart.com/laminate/consumer/products/index.asp
they give you free samples and you dont pay shiping..WHY NOT !:D?
Also you only need like 2x4 sheet right(since you are only dont the panel)?

good luck with laminate (i love laminate btw...the looks is just nice and clean).

[MrBond]

Scott says on his site that he used aircraft shears to cut out the laminate.   Then he used a laminate cutting bit in a router to align it to his cabinet.  Do I need these shears to cut out the basic shape, and then modify with the router?  I can borrow a router, but I'd need to buy the shears and the bit.  So when I go to the hardware store, do I look for "laminate cuting bits"?  
Also, I'm kind of liking the $10 plexi cutter.  I have a jigsaw.  Did this work well for you Snaaake?  No breaking?

[Darkstalker]

Also, I'm kind of liking the $10 plexi cutter.  I have a jigsaw.  Did this work well for you Snaaake?  No breaking?

I'd be real cautious with a jigsaw.  I would think a bandsaw would be easier since it only cuts/spins one direction so you can maintain the higher speed that you need to cut plexi.  Try cutting some scrap pieces (Or what will be scrap pieces) to get a feel for it if you're going to try it.  Key things are high speed, and cut slow...

[MrBond]

I've also heard of using a utility knife and scoring the laminate from the top with a straight edge and then snapping it on the scored line.  Anyone try this?

[SNAAAKE]

Also, I'm kind of liking the $10 plexi cutter.  I have a jigsaw.  Did this work well for you Snaaake?  No breaking?

NOOOOOOOOO....dont try..

Jigsaw is not for this..plexi glass cutter works really well..i wish i can post a picture of the one i have now..dont have camera but go to your local hardware and ask for the best plexi cutter.I didnt use router because i didnt have one(i thought its complicated with all the bits and stuff so i took the easier way around )..good luck though.

[SNAAAKE]

I've also heard of using a utility knife and scoring the laminate from the top with a straight edge and then snapping it on the scored line.  Anyone try this?

This is exactly what you do but NOT with utility knife.

with plexi glass cutter..its REALLY easy.Trust me..whole process took me about half hour(not counting the time to let the cement dry).

[tma]

Hi MrBond,
here's my cab I did with formica:
http://mywebpages.comcast.net/thomas3120/T's%20Arcade%20Cabinet/T's%20Arcade%20Cabinet.htm

<-T->

[ITrek]

Home Depot sells a laminate cutter for $6 that looks like a utility knife with a dull very thick blade.  You just drag this cutter across the laminate a few times to score it and it will break along the score nicely.  I used this on my cab and it worked great.  Would have been nice to have a power cutter but this is a pretty cheap alternative that works well.

[MrBond]

thanks guys!  tma, your cab is awesome!  Yours too Snaaake!  I can only hope mine looks half as good when I'm done!  I'm going to look into that laminate cutter.  Sorry Snaaake, I misunderstood, I thought you meant you bought a blade for your jigsaw to cut plexi, not a seperate cutting knife.  My mistake!  

What about these "Down cutting laminate blades" made by DeWalt that I saw?  Will they work???

[MrBond]

Ok, how do I drill the 1 1/8 holes for the buttons and joysticks?  Howabout the hole for trackball and spinner?

Thanks

[Silverwind]

Ok, how do I drill the 1 1/8 holes for the buttons and joysticks?  Howabout the hole for trackball and spinner?

Thanks

For the buttons and joysticks... pick yourself up a 1 & 1/8 wood boring bit from your local home depot/lowes..  mine was about  5-6 bucks and it works pretty good...

*EDIT*
http://www.tools-plus.com/irw88888.html
check that link.. that is what they look like (the one I have at least)

[eightbit]

Forstner bits give a much smoother hole and produce less chipout on the top and blowout on the bottom.

Use the same bit for joysticks.

Trackballs and spinners all depend on your mounting method.

[Silverwind]

Forstner bits give a much smoother hole and produce less chipout on the top and blowout on the bottom.

Use the same bit for joysticks.

Trackballs and spinners all depend on your mounting method.

unfortunatly I already bought the previous bit  Didn't see the other one.. (are they available at lowes?)

[rampy]

Forstner bits give a much smoother hole and produce less chipout on the top and blowout on the bottom.

Use the same bit for joysticks.

Trackballs and spinners all depend on your mounting method.

is a forstner bit a fancy name for a hole saw drill (is tat hte right term? the one with the mandrel and round hole cutting thing) or is it a spade bit or something else?

rampy

[Silverwind]

Forstner bits give a much smoother hole and produce less chipout on the top and blowout on the bottom.

Use the same bit for joysticks.

Trackballs and spinners all depend on your mounting method.

is a forstner bit a fancy name for a hole saw drill (is tat hte right term? the one with the mandrel and round hole cutting thing) or is it a spade bit or something else?

rampy

I think spade is the one I got.. doesn't work too bad.. could be better.. cuts through the wood pretty quick just have to be careful not to splinter the back..

[ITrek]

I agree, use a Fostner bit for nice smooth hole.  Those bits look like this.

[Silverwind]

I agree, use a Fostner bit for nice smooth hole.  Those bits look like this.

how much do they run?

[ITrek]

At Home Depot a 1 3/8" bit costs $19 (ouch!).  However, you can by a whole set of Fostner bits at Home Depot for $39 that has about 14 bits in the set.  Same brand too, go figure.

[TazMan]

I think spade is the one I got.. doesn't work too bad.. could be better.. cuts through the wood pretty quick just have to be careful not to splinter the back..

With a spade bit to avoid splintering you may want to try boring through part way on side 1.  When the tip pops through Side 2, flip it over and finish from the other side.

YMMV  *shrug*

[beek]

You can also use a tablesaw to cut the rough shape.  Just make sure you have a good blade and put the good side down when cutting.  Way faster then any other way I've tried.  

[MrBond]

So just a hole saw (or Fostner bit) with drill and a jigsaw would work on laminate?  Was my post clear?  I wrote in the subject of my post "Drilling holes in laminate?"  Do'h, I didn't mention it in the post itself.  Sorry, I meant "Ok, how do I drill the 1 1/8 holes for the buttons and joysticks in (laminate)?  Howabout the hole for trackball and spinner (in laminate)?
The spinner only needs a small hole, while the trackball needs a larger hole.


Thanks again!

[eightbit]

So just a hole saw (or Fostner bit) with drill and a jigsaw would work on laminate?  Was my post clear?  I wrote in the subject of my post "Drilling holes in laminate?"  Do'h, I didn't mention it in the post itself.  Sorry, I meant "Ok, how do I drill the 1 1/8 holes for the buttons and joysticks in (laminate)?  Howabout the hole for trackball and spinner (in laminate)?
The spinner only needs a small hole, while the trackball needs a larger hole.

The best way to trim the laminate to your control panel is with a router flush cutting bit. You could also make your control panel over size and then laminate it and cut it down to size but test whatever method you use to cut it on a scrap peice first to make sure its not going to chip out.

After you attach your laminate to your control panel and trim it flush. You can then drill holes through the laminate and your control panel at the same time. A forstner bit is best for this. Cut from the top down.