Need help putting formica on my workbench

[sixdogs]

I am thinking of putting either formica or melamine down for the light duty top work surface on my bench and have a couple of questions I hope someone can answer. The bench has 3/4" plywood on the top that's screwed down. I figure I can unscrew the top, trace the top onto the laminte and cut it little oversize. Then I can clamp it to the plywood and use a trim router bit to make the formica the same size as the top. Then I reinstall the top and glue down the perfectly fitting formica. But I may use melamine.

My questions are 1) if I cut a laminate like this, do I cut it with a circular saw right side up or upside down? And 2) Will a trim router work on melamine or formica or will it just shatter the edge? Does anyone know?

Here's a pic of the bench when I first finished it. That was the cleanest it ever was.




Melamine is an old hot rodders trick because it's easy to clean and when it's damaged you just peel it off and put another down. I have a 4 x 8 rolling table like this but I have never cut a sheet. I also have some metal tables so no need for metal. This is just a light duty work surface that I want to be able to wipe clean from light use. Any ideas appreciated.

 

[dave1949]

There is a Formica router bit. I did this once many years ago but IIRC you rout off the overhang after the contact cement glue has dried. If you don't have a good smooth, void-free surface, for Formica I would put down a thin layer of mahogany plywood or Masonite first.

 

[turnkey4099]

I'd use Formica, much harder and will last longer. It also can be peeled, used a torch and heat it, comes right off. Use a good rubber mallet to hammer on it to be sure it has good contact.

Glue the formica to the top and then use the router with a formica bit to trim it. One pass and done. The bits come with roller guides and in several varieties from straight to angles.

Harry K

 

[charlz]

Yep, same experience as Dave, contact cement and then a router with a trim bit to finish the edges... at least for Formica I would think Melamine is the same.

 

[Ford850]

I've been using Masonite on my benches. I screw it down with 3/4" screws, countersinking the heads so they are flush. I like how it is smooth and hard, absorbs oil and messes, and can be wiped clean (but stained). I intended to replace it every so many years, but so far it's still holding up great. The Masonite on my benches in my wood shop are all like new after 20 years. The Masonite on my barn bench is getting oil stained and abused a little after 10 years, but still works well. Even when oil stained, it wipes clean and doesn't contaminate the next project I set on there.

 

[Otto Syracuse]

I agree on the Masonite. I glued and screwed it to 3/4" plywood over 20 years ago and then added a 3/4" x 5/8" piece of edging to the front of that. It has held up great and I like the surface. Smooth and hard, and if I screw through a piece of wood into the surface, I won't damage it like it would with laminate.

 

[newbury]

3rd vote for masonite. I figured I'd be replacing them every few years, so far no problem.

I've about 100 linear feet of pallet racking varying between 42 to 48 inches wide, beams 8' to 8.5', and 8' to 12' tall. I put the first shelf about waist high and the second shelf about head high, with subsequent shelves at heights for boxes etc. I've been dropping in 4 or 5 "joists" between the beams and then a "cut to size" sheet of 3/4 PT plywood, then dropping a 3/4 sheet of masonite on top. No glue, no screws. The masonite is "sacrificial", I figure I can cut out and replace a piece if I have to, but so far I haven't for three years (knock on masonite).

I've had formica tops before but a dropped hammer would chip it, plus the masonite was only $7 a sheet.

 

[sixdogs]

Wow, thanks on the masonite. I was aware of it but forgot and never even considered it. I need a moment but think that's what I'm going to go with. It's easier, cheaper and that works for me.

 

[dave1949]

Wow, thanks on the masonite. I was aware of it but forgot and never even considered it. I need a moment but think that's what I'm going to go with. It's easier, cheaper and that works for me.

AND ... you don't have to pick the color or pattern. :laughing:

You could coat the Masonite with spar urethane to give it some more wipe-ability and moisture resistance--for water based stuff at least.

 

[JerryK]

Have you thought about oak flooring...? Makes a great top cover, able to take a lot of abuse/hole drilling/etc. Put it in and varnish it good, and it will even shine for many years...