When to cut Formica?

[str1der]

When building a CP should you apply your formica before you cut all of your holes?

[eightbit]

When building a CP should you apply your formica before you cut all of your holes?

yes

[Birdtales]

Actually I did not on my first CP. I applied it after I drilled all of my holes and then trimed in those holes with the router and a flush trim bit just like most do with lexan.

[str1der]

eightbit,
              What kind of precautions did you take to insure you didn't damage the formica?

[eightbit]

eightbit,
              What kind of precautions did you take to insure you didn't damage the formica?

I've never done a CP in formica but I have drilled counter tops. You should get good results with drilling from the formica side down with a forstner bit.

[OSCAR]

Actually I did not on my first CP. I applied it after I drilled all of my holes and then trimed in those holes with the router and a flush trim bit just like most do with lexan.

If I were to use Formica on a cp, this is exactly how I would do it, too.  Assuming you have access to a router & good straight bit, this is probably the best way to ensure you don't crack/chip the Formica.  You can't get a cleaner cut than you can make with a router and good bit.  As a side note, when using routers on composites or polymer materials, always be sure to move in a clockwise direction with the router (same direction as the cutter head spins) to avoid chipping the material you are routing.

 

[dac]

I had the holes drilled for the buttons before applying formica.  Once I applied the formica and let it cure, used a drill bit slowly! through the center of the hole, I think it was a 3/4" bit.  
once that was done, I had a 1/2" formica trim bit for my router and trimmed out the rest of the button hole

The drill did chip slightly sometimes, when I went too fast.  but the second step, once the 3/4" hole is done, took care of the chips... slowly is the key... and test!

Hope this helps

[Brax]

You may get chipping when drilling through the formica. It's best to have your holes drilled in your control panel first, apply your laminate, then trim it up with the router. You'll get a perfect trim every time. No fuss, no muss.

[eightbit]

You may get chipping when drilling through the formica. It's best to have your holes drilled in your control panel first, apply your laminate, then trim it up with the router. You'll get a perfect trim every time. No fuss, no muss.

No arguement that a router is the best way to go, if a router is not available I stand by my first suggestion, the forstner bit.

[str1der]

Do you drill a hole first then use a router to cut back the edges?

[Birdtales]

Do you drill a hole first then use a router to cut back the edges?

You have to drill a hole large enough for the router bit to fit in to.

[Brax]

Laminate trim bits have a bearing on the bottom, so you drill a hole just big enough for the bit to fit through. (chipping doesn't matter here because you'll trim out all that material)

[Ted_Striker]

Chipping can be minimized by putting a piece of wood under your formica.  I took a 2x4 scrap, put an old piece of felt on it(so it wouldn't scratch anything... my 2x4 was construction grade) and layed my cp hole on the wood and drilled through.... virtually no chips....  but as others have said, chips aren't that critical as you will trim away most of the area with the router.  

Just passing this on:).

[Tiger-Heli]

A similar method for those too cheap to buy a router is to drill the holes in the wood panel, glue the formica down, and then use a dremel with a #115 cutter bit
http://www.dremel.com/productdisplay/display.asp?sku=115&color=009999 to trim the formica to the button diameter and use a whizz-wheel on the dremel to cut the underside of the Formica flush with the wood.  You wont get anywhere near as clean a finish as a router, but all damage will be covered by the button lip, screw heads, etc.

[str1der]

Has anyone here ever used pre-laminated counter top pieces for a control pannel. I found some short sections at loews that are laminated and not to expensive. Do you think there would be a problem cutting out the shape then using a forstner bit to cut the holes? When cutting something like that what would you use.

[eightbit]

Has anyone here ever used pre-laminated counter top pieces for a control pannel. I found some short sections at loews that are laminated and not to expensive. Do you think there would be a problem cutting out the shape then using a forstner bit to cut the holes? When cutting something like that what would you use.

How thick pre-laminated are you talking about? Most counter tops are probably to thick.

As far as cutting it to size you want to use a high tooth count blade. A table saw would probably be best but you could use whatever saw you have access to. You can center masking tape down your cut lines before you cut and you'll be surprised by how much this will help prevent chip out.

For drilling the holes a forstner bit would be fine. If you drill from the laminate side down you should have a very clean hole.

[str1der]

When you say from the laminent side down do you mean the bit would touch the laminent first? I'll have to check on the thickness but it looked like 3/4" except for the front rounded edge.

[eightbit]

Yes the laminate first from the top down. Even fostner bits won't always make a really clean exit hole but you shouldn't be able to get a cleaner entrance hole when using one.