On Wed, 29 Sep 2004 20:06:23 -0400, "Dick Snyder"
scribbled:

I am making Norm's Router Station.(
http://www.newyankee.com/getproduct3.cgi?813). The top has high pressure
laminate (like melamine) bonded to it. The dimensions of the top are such
that I would have had to buy a 4' x 8' sheet to have a single piece to bond
to the top so instead I got two pieces 2' x 4'. I need to cut both sheets
and here is my question.



I have searched the web and there seem to be two general approaches to
cutting this stuff. One is to score it deeply on the back and then cut it
with a jig saw maybe using masking tape to minimize the chip out. The second
approach seems to be to do it with a table saw taking care to prevent the
melamine from slipping under the fence (see
http://www.cabinetmaking.com/laminate.htm). I'd like some input from the
readers on this group as to the way that has worked best for you.

I have been unsuccessful in cutting melamine covered particle board
without chip-out, even with Freud's ulitimate melamine saw blade, tape
etc.. When absolutely no chip out is essential, I cut about 1/8"
oversize on the table saw and then trim it to size using a router with
a straight bit and a straight-edge to guide the router.

If you mean high pressure laminate like Arborite or Formica, the same
principle applies. I cut oversize on table saw, glue it on & then trim
it using a bearing guided straight bit on the router.

Luigi
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