Cutting MDF / Laminate

[Minwah]

I have a question I'm not sure the answer to having not really worked with laminate before...

I need to make an MDF panel laminated with Formica, with a large (280mm x 100mm ish) rectangular cutout in it. If it were just MDF I would jigsaw the rectangular hole slightly smaller than required, and then use a router with guide and flush-trim but to cut to the exact size. But as I want to laminate the MDF, can I do this after laminating? Can I jigsaw laminate without ruining it?

OR should I cut the hole in the MDF before laminating? If so, would it then be ok to just drill a hole through the laminate and flush-trim the laminate to the wood?

Thanks for any tips!

[Minwah]

(sorry mods, this was meant for Woodworking, could you move please?)

[eds1275]

I would personally cut the wood to size first making sure it's perfect, and then glue the laminate on, drill a pilot and flush trim.

[wp34]

My brother in-law helped me make just such a cut on my Tron Legacy project.

http://forum.arcadecontrols.com/index.php/topic,116519.msg1254958.html#msg1254958

If I had it to do over again I would do as eds1275 suggested.  My brother in-law is a professional carpenter and we still messed up the cut slightly.  Not a huge deal since it is on the back but it still bugs me a little.

[sabreerbasAlpha]

I would personally cut the wood to size first making sure it's perfect, and then glue the laminate on, drill a pilot and flush trim.

100% This way. ^^^^ from eds1275

The flush trim Router bit will be like a hot knife through butter on the Laminate. Just take your time don't go doing it a 100 MPH. Slow and steady is the way my friend.

[Epyx]

Minwah, I have an informative tutorial on this in my signature.  Agreed with above though...cut panel first...glue rectangular laminate on it...then flush trim with router for a perfect finish.

[rablack97]

Same concept, just be careful when rolling, if you hit the hollow part hard you will crack the formica.  Do this on a warm day and maybe set the formica out in the sun a bit...Warming it up makes it more flexible and less likelly to crack on you.

My best investment was a rigid hand laminate trimmer, so much easier than a full size router.

[shponglefan]

I concur with cutting/drilling the MDF first, then applying the laminate, drilling pilot holes and finally flush trimming.  I do not recommend trying to use a jigsaw with laminate as I believe that could easliy crack/splinter it.

Also, I second rablack97's recommendation of getting a laminate trimmer.  I opted for a Rigid laminate trimmer from Home Depot and it's a breeze to trim laminate with it.  But a regular router works just fine, too.

[Minwah]

Thanks everyone for the replies and links - that has really saved me working this out the hard way!

[eds1275]

hard... and expensive way.

[mountain]

I have done it both ways with success. It's all about having the right tools I suppose. If your bit selection is limited, yeah, do all cuts first. I used to build speakers and would occasionally just build them first with laminate/wood veneer, then cut the holes. The trick was to use a down cutting trim bit in the router attached to a circle cutting jig. This prevents the laminate from pulling up during the cut. I machine pre-laminated parts for my jukebox kits to get a cleaner cut and just use a down spiral bit. A jigsaw with its upward cutting motion will definitely create a lot of tear out and a heavily chipped edge.