I am making a router tabletop out of 1/2" corian. The Insert is 3/8",
leaving 1/4" of corian. That might be strong enough, but I sure don't want
to chance it. I would like to reinforce the bottom. I can glue plywood or
more corian to the bottom around the cutout to strengthen it.

Would plywood (1/2"?) be adequate, should I use corian, or something else?
Is epoxy a good choice for the glue, or maybe polyurethane?
Is glue adequate, or should I work some bolts into it as well?

Toller wrote:
I am making a router tabletop out of 1/2" corian. The Insert is 3/8",
leaving 1/4" of corian. That might be strong enough, but I sure don't want
to chance it. I would like to reinforce the bottom. I can glue plywood or
more corian to the bottom around the cutout to strengthen it.

Would plywood (1/2"?) be adequate, should I use corian, or something else?
Is epoxy a good choice for the glue, or maybe polyurethane?
Is glue adequate, or should I work some bolts into it as well?

Hello Toller:

I like the idea! Corian sink cutouts ought to be readily available;
might try that myself....

One issue with plywood is differential expansion. If the plywood
absorbs moisture it may swell, and the table might not remain flat. I
would either use 3/4" corian or glue another piece of corian---at least
a few inches wide if not full width---under the groove for the insert.

Polyurethane glue holds like the dickens, but it also expands
significantly as it cures. The "slow" or 2 hour epoxy sold at hobby
stores is about $8-10 for two 4 oz bottles and should work well. Sand
the surfaces and clean thoroughly before gluing.

Best -- Terry

By the way Toller, 1/2 minus 3/8ths equals 1/8th. Glue more Corian
rather than ply for reasons stated by another poster. A couple/few or
four countersunk fasteners are a great idea. Corian does flex and needs
reinforcement as close to your router plate as possible. Tom
Toller wrote:
I am making a router tabletop out of 1/2" corian. The Insert is 3/8",
leaving 1/4" of corian. That might be strong enough, but I sure don't want
to chance it. I would like to reinforce the bottom. I can glue plywood or
more corian to the bottom around the cutout to strengthen it.

Would plywood (1/2"?) be adequate, should I use corian, or something else?
Is epoxy a good choice for the glue, or maybe polyurethane?
Is glue adequate, or should I work some bolts into it as well?

"Toller" wrote in
:

I am making a router tabletop out of 1/2" corian. The Insert is 3/8",
leaving 1/4" of corian. That might be strong enough, but I sure don't
want to chance it. I would like to reinforce the bottom. I can glue
plywood or more corian to the bottom around the cutout to strengthen
it.

Would plywood (1/2"?) be adequate, should I use corian, or something
else? Is epoxy a good choice for the glue, or maybe polyurethane?
Is glue adequate, or should I work some bolts into it as well?




Glue the entire piece of Corian to a 3/4" substrate,preferably birch
plywood for rigidity;otherwise,the Corian will eventually sag from the
weight of the router.

Epoxy is fine,the right kind,of course.
I'd use West System or System Three and the right filler.

--
Jim Yanik
jyanik
at
kua.net

"Jim Yanik" wrote in message
.. .
"Toller" wrote in
:

I am making a router tabletop out of 1/2" corian. The Insert is 3/8",
leaving 1/4" of corian. That might be strong enough, but I sure don't
want to chance it. I would like to reinforce the bottom. I can glue
plywood or more corian to the bottom around the cutout to strengthen
it.

Would plywood (1/2"?) be adequate, should I use corian, or something
else? Is epoxy a good choice for the glue, or maybe polyurethane?
Is glue adequate, or should I work some bolts into it as well?




Glue the entire piece of Corian to a 3/4" substrate,preferably birch
plywood for rigidity;otherwise,the Corian will eventually sag from the
weight of the router.

Epoxy is fine,the right kind,of course.
I'd use West System or System Three and the right filler.

I have a half gallon of Wests just a few feet from my router. Is there any
household product I can use as a filler, or must it be purchased? I have
used sawdust as a filler before, but not in an application where failure
could be hazardous.

"Toller" wrote in
:


"Jim Yanik" wrote in message
.. .
"Toller" wrote in
:

I am making a router tabletop out of 1/2" corian. The Insert is
3/8", leaving 1/4" of corian. That might be strong enough, but I
sure don't want to chance it. I would like to reinforce the bottom.
I can glue plywood or more corian to the bottom around the cutout
to strengthen it.

Would plywood (1/2"?) be adequate, should I use corian, or
something else? Is epoxy a good choice for the glue, or maybe
polyurethane? Is glue adequate, or should I work some bolts into it
as well?




Glue the entire piece of Corian to a 3/4" substrate,preferably birch
plywood for rigidity;otherwise,the Corian will eventually sag from
the weight of the router.

Epoxy is fine,the right kind,of course.
I'd use West System or System Three and the right filler.

I have a half gallon of Wests just a few feet from my router. Is
there any household product I can use as a filler, or must it be
purchased? I have used sawdust as a filler before, but not in an
application where failure could be hazardous.




West makes several different fillers,one of my favs is fumed silica.
Other fillers are plastic microfibers,chopped glass fibers,phenolic
microballoons,and wood dust. Fibers add strength and crack
resistance,microballoons are for lightweight filler.Fillers are mainly used
for gap-filling and anti-sag or no-drip properties,or for "fairing";filling
in the weave of glass cloth in fiberglassing. Only the fiber fillers add
strength.


System Three's website has a free download of The Epoxy Book,a great guide
on how to use these types of epoxy and fillers.

With wood underlayers,you need to first apply a coat of unfilled epoxy for
the wood to absorb,otherwise you get a glue-starved joint.

IMO,that spray-on contact adhesive for laminates would be the easiest glue
to use.


--
Jim Yanik
jyanik
at
kua.net