Need a little help with laminate - Woodworking Talk

rrbrown · 02-24-2009, 10:46 AM

This may seem trivial but I have worked with almost everything from metal to plastic but have never actually cut and laminated anything myself. I need to cut laminate for my out feed table. I'm laminating the sides which are 2 1/2 inches first then the top. I know about the process and the trim router to finish it after it is on the table. What I'm not sure of is the best way to but a 3" strip 6 ft long so I can glue it on. Any help would be greatly appreciated.

Tony B · 02-24-2009, 11:16 AM

and I assume you are working alone, make the strip 1/2 wider and 1/2" longer than needed.
Make sure edge of surface is nice and flat and area is very clean.
After you put your two coats of contact cement on the edge and the laminate let it dry till no longer tacky. Usually about 5 to 10 minutes.
I am a righty so I like to start on the laft side and work toward the right. Pick up your piece in both hands and bend it in a large bow that is easy to hold without stretching your arms. Hold it in a horizontal position and 'hover' over the left corner with the laminate centered top to bottom and leave about a 1/4" overhang in the back. Hold your breath, wait for that testosterone rush and stick the piece onto the surface for about 2 or 3 inches worth. You are still holding it in a bow shape. Now slowly, not real slow but at a comfortable pace, walk along the edge making a 'rolling' contact as you go. When the whole thing is attached, use your laminate roller and start from the middle and press it out in one direction than the other. Now trim it flush.
Dont be nervous, if you really screw it up, just pour some lacquer thinner or acetone on the joint and it will peel right off. Wait for it to dry and put on another thin layer of fresh contact cement and try again.
It;s really easier than it sounds. Take a deep breath, relax and make like you have done this before.

I wont say 'good luck' because you wont need it. Just relax and do it.

rrbrown · 02-24-2009, 11:32 AM

Thanks for the reply, I will probably have a helper especially for the 4' x 6' top but the advise helped confirm most of how I was going to attack it. You seem to leave out the most inportant part. LOL I'm not sure what is the best thing to cut the strip off the sheet. I was thinking band saw, but If there is anything else that is easier or better please let me know.

Tony B · 02-24-2009, 12:05 PM

Cut your oversized top first. Then you will have smaller pieces to work with. I cut pieces 8 ft long and 3/4" wide on my Table Saw.
Hold the laminate face up and bowed up and slowly unravel as it goes through the saw. Its scarey but not bad.

The main thing is that you dont want the laminate to get jammed under your fence. I use a scrap of MDF or plywood, whatever I have handy. It should be just a little bit longer than your fence and set down tight against the TS top. Then clamp it to your fence and all should be OK.

As for the edge gluing, this is really a one person operation.
The top will require more attention. You will need something to space the top laminate from the table top. I use steel rods about 3/8" diameter. I usually lay them down on the top about 6 to 8" apart. I cut the top about 1/2" total oversize on both length and width. Lay the top laminate on top of the rods until it is well centered all the way around. Again, wait for that testosterone rush, then push down in the middle until you are sure that you made some contact. Now prepare to work one side at a time. Starting in the middle where you made contact pull out one rod at a time and press as you go. When you get to the end do the same in the other direction. After that, you know the drill.
OK, let me digress a little. Remember when I said pull out the rods one at a time? I lied. Usually the rods are 3 foot long so you will probably use them in pairs. Side by side overlapping in the middle and overhanging on the ends. I just didnt want to confuse the procedure with this thrown in the middle.

YOU can use almost anything instead of the rods. I have even used old Venetian Blind slats before. You can use wooden dowels but they can get messy. With the steel, just wipe clean with a rag wetted with lacquer thinner or acetone. The steel rods are a good investment. After you laminate your outfeed table, you will become a laminate junkie and use these rods on a regular basis.
After reading a lot of articles on laminating I was absolutly terrorfied at the thought of doing it. The first time I did it, an experienced friend helped me. After a few minutes we were done and all I could say in astonishment is "That's it? We're done? That's all there is to it?". It's a long funny story, I'll go into some other time.

When I used to teach furniture making and woodturning, I always told my students. "It's only a big deal if you make it a big deal. Take a deep breath, relax and make like you have done this before. Remember, this is supposed to be fun"

So, have fun.

rrbrown · 02-24-2009, 12:32 PM

Do I need any certain blade ? I thought that the laminate would chip or brake easy when cutting with a tablesaw.

Thanks again,
I will post pictures later this week or when I finish the table. I am working on all the cabinets, storage, outfeed table and workbench in my shop. So I will be busy for the next couple of weeks. Hard to work around all the stuff laying around in the shop, got to get this finished.

Tony B · 02-24-2009, 12:37 PM

Nothing special. I do use a zero clearance insert on my table saw. Make your piece at least 1/4" wider than you need and you will be just fine.
A band saw will also work but large sheets of laminate are a booger to handle that is why I use my TS.

skymaster · 02-24-2009, 12:49 PM

RR; If you have a tablesaw, that is the easiest way to cut it. If u have a delta unifence, use the fence flat with the 1/2 face toward the blade and let the edge of laminate run over it and slide along the curve. Second,way, get a good long strait pc of wood, place it UNDER the lam as a guide,use the router and the trim bit.
What ever fence you have MAKE VERY SURE that the lam does NOT slip under the fence. You could even use a pc of cardboard UNDER the fence to let the lam run on top of so it wont.