Need help from Laminate experts...

[m_mcgover]

I am thinking about re-doing the sides of my cabinet using formica black laminate.  On one side of the cabinet (3/4" plywood sides), there is a circular hole cut all the way through to allow for airflow (fan gets mounted on inside).  Surrounding the circular hole is a square grill on the outside that sits flush with the cabinet side because of a square routed hole (about a grill thickness, so likely 1/16" - 1/8").  A non-scale picture is attached showing the situation.

What is the best way to approach this?  Do I try to pre-cut the square hole in the laminate and line it up during application?  I know that is tough since once the cement comes in contact, it sets immediately.

Maybe i can create some kind of jig to help with aligment?

Or, do I try to cut the square hole afterwards?  How do I do that and line it up w/o screwing up the new laminate?

I need advice/tips/help on this one!

Thanks!!

[HaRuMaN]

Cut the square hole afterwards.  Use a router, and a flush trim bit.

[HaRuMaN]

Err... looks too shallow to use a router... hmm

[Epyx]

Here is what I would do:

Use a piece of scrap, I would use 1/2".  Route out an identical fan square in the scrap that goes through the entire 1/2".  Then just flush trim your laminate to the square (using a bottom bearing trim bit) you cut out in the scrap approximately where it will be on the rough untrimmed laminate.  Then that piece you just routed out on the laminate (the square fan hole) becomes your  clamping point.

So you line that square up with the proper fan square below. Use the stick method in my lamination tutorial to assist you in lining it up for gluing...then just trim the edges.

[m_mcgover]

Sorry to be dense (I am a newbie wood-worker)....can you provide more details...I still don't follow.

I get that I end up with a scrap piece of wood with an identical square hole that goes all the way through.
Sounds like I then cut a hole in the laminate first using this scrap
Then I try to align the square hole in the laminate to the square route in the cab side when I glue it down?  I guess press the laminate here and work outwards?
Is that right?

[Epyx]

Yes, have a read of my lamination tutorial for more detail (in my signature)...but yes you cut the square first roughly where you need it using the scrap template.  Then apply glue to both sides (Laminate/Wood) use sticks (IMPORTANT) and then remove the sticks around the square to line it up.  


Doing it this way is imo the easiest way...trying to trim to size first is the painful way of doing it

[m_mcgover]

And when you say "trim the edges" you mean the edges of the cabinet and not the edges around the square...right?

(and thanks, by-the-way)

[Epyx]

Correct...that would be your final trim once the glue is set as you have already trimmed the square pre-joining.

No problem, msg me if you have additional questions but the tutorial shows the stick method.  This will ensure you are able to line it up pre-joining.