I am making a special table which requires specially shaped Formica pieces, but I don't have any experience with cutting laminates like this and need your advice.
Here are the dimensions of the Formica need: a) two 4" x 47" strips b) two 4" x 27" strips which have an 3" x 8" section removed from the middle.
I understand that covering the edge to be cut with tape is essential, but is standard masking tape all that is needed and do I put it on both sides of the sheet?
I've read that a router is the best way to cut it, but I will have to use a handheld rotary power saw. Sears had a 200 tooth low profile blade which was designated for cutting veneer. Is this the best kind of blade to use?
Should I clamp it between two pieces of wood as well as use the tape?
How deep should I set the depth of cut? What I mean is should I be cutting 1/2" deep or should I try to keep the depth of cut just slightly more than the laminate thickness itself?
Also, does it matter which side I cut from?
In order to cut out the 3" x 8" section, should I drill large holes at the inside corners and make straight cuts to them?
Are there any special requirements for drilling through Formica?
Your assistance in greatly appreciated. Thanks in advance.