How to Mitre a Worktop using a Router & Jig
How to Cut Sink Hole in a Worktop
Installing a Laminate Worktop
Fitting a Laminate Part 1
Fitting a Laminate Part 2
How to Fit an Earthstone Solid Surface Worktop
- Hand Held Circular Saw
- Edge Clamps
- Hand Router
- Cleaning Solvent
- Hand Plane
- Seam Adhesive
- Random Orbital Sander
- Silicone Sealant
- Palm Sander
- Aluminium Tape
- Electric Drill
- Fibre Reinforced Tape
- Mitre Jig
- Jointing Bolts & Biscuits
- Edge/Profile Trimmer
- Finishing Polish & Cloth
- 10mm Spanner
Hand Held Circular Saw – use a circular saw with high quality TCT triple chip blades for a fine finish cut. A hand router must be used for the final sizing of exposed edges. Allow at least 5mm oversize for final pass.
Hand Router – with variable rotation speed and high quality double flute tungsten carbide tipped cutter is used for straight cuts, mitre joints and cut-outs.
Hand Plane – use for removing excess adhesive from joints once adhesive has hardened.
Random Orbital Sander – to sand Earthstone worksurface use a good quality random orbital sander. Wilsonart recommend Festool random orbital sanders with dust extraction for an excellent professional finish.
- 180 grit first stage to remove excess material from joints
- 240 grit second stage to smooth over joints
Palm Sander – a good quality orbital palm sander is for finishing the front edge.
Scotchbrite Pad – for final finish use an ultra fine Scotchbrite pad.
Electric Drill – use a good quality variable speed drill with 1/2″ chuck. Standard high speed drill bits are suitable for Earthstone worksurface.
Mitre Jig – forming mitre joints and position cut-outs for connector bolts.
Edge/Profile Trimmer – trimming overhanging edges, use a fixed tip guide trim cutter with a 3mm profile cutter.
Edge Clamps – A type clamps are used to apply edging, G type to secure jigs to the worksurface.
Cleaning Solvent – cleaning surfaces thoroughly prior to bonding.
Seam Adhesive – 50ml cartridges with colour matched adhesive used to bond mitre joints and edging. Applicator gun with mixer tips also required.
Silicone Sealant – waterproof & mould resistant sealant for all exposed raw core against moisture.
Aluminium Tape – reflective tape used to reduce the heat transfer between the hob and internal cut-out.
Fibre reinforced Tape – to temporarily secure the edging to the worksurface if additional edging is required. Tape is removed when adhesive is set.
Jointing Bolts & Biscuits – bolts are used to clamp joints and the biscuit joints help to strengthen joints and produce a level surface.
Finishing Polish & Cloth – Countertop Magic recommended for final surface polish.
Cutting & Jointing
Earthstone worksurfaces are hardwearing and require good quality machinery and clean, sharp cutters to produce a good professional finish and ultimately save time and effort. (See recommended tools under installation tools).
Cutting Earthstone Worksurfaces
Cutting of Earthstone worksurfaces can be carried out using a portable hand-held circular saw. Ensure a good quality sharp triple fine tooth tungsten carbide tipped blade is used and make two cutting passes:
- 1st cut set saw blade depth at 10mm,
- 2nd cut set saw blade depth at 40mm.
Final trimming should be made with a router. Allow 5mm oversize to trim to the final size with the router.
Position the worksurface to begin cutting in from the factory fitted edge.
Never finish the cut through a fitted edge. Always proceed carefully when cutting towards and through the front edge, this will reduce the possibility of chipping or flaking. Ensure the cut is cleaned to allow for a good bond and finish to the joint.
All joint edges and final finished ends must be cut using a hand router with a sharp blade.
Straight & Mitre jointsTo ensure a clean square edge use a straight edge guide offset to suit the router for both end and butt joints.
To minimise material waste we recommend a 90° mason’s mitre joint using a purpose made jig. Refer to jig manufacturer’s instructions.
It is recommended to router through the worksurface in 3 incremental stages with the worksurface positioned as follows:
- Left hand 90° joint
- Female joint router face up
- Male joint router face down
- Right hand 90° joint
- Female joint router face down
- Male joint router face up
Cut-outs – sinks & hobsCut-outs can be formed using a hand router and a suitable jig or template.
Clamp the jig to the face of the Earthstone worksurface and cut round in 3 stages of 12mm depth increment. Similarly with a template mark out the desired cut-out using a pencil again following the outline and cutting in 3 stages. Always ensure all internal corners of the cut-out are rounded using a drill with a minimum 10mm radius.
Thoroughly clean the edges of the cut-out and the surface ensuring all dust and shavings have been removed.
Sink cut-outs must be completely sealed using a 2 mm thick bead of clear, water resistant silicone.
All hob cut-outs require a 50mm wide heat reflective tape around all the raw edges making sure the tape overhangs both the surface and underside of the cut-out.