Seaming Formica is tough, especially if you donít have the right specialty tools. The seam will no-doubt always be noticeable, especially in a pattern. Consider these options:
∑ Get a bigger sink. This would depend on what your base cabinet under the sink can accommodate, but there are some sinks that have a built-in rinsing tray or something, which would allow for a bigger surface footprint, and still fit within the base cabinet. Measure different ones. Maybe one is just big enough for your needs. If your current sink is new, maybe you can still return it. ∑ Take your excess material and bond a 1" strip all the way around the sink, right on top of the damaged section, and under the sink lip. This might not look bad depending on the color of the top, and how it is done. Make sure the damaged area is nice and flat. Experiment first by placing the material around and under the sink lip. Donít bond until youíre satisfied with the look. If you do not have enough material to go all the way around, you may be able to buy more, or get some of that edging stuff they sell to finish counter edges. Itís about 1 Ĺ" wide, and usually has finished edges already. Talk to your Formica supplier and see what he has. ∑ Do some sort of tile/wood sink surround. This will raise the sink somewhat higher than the Formica strip idea, but that may not be a problem. If your counter is wood-edged already, matching the wood might also look good, but keep in mind there is a lot of water this area. Tile is more durable in this environment, but I canít vision how it would look. As before, make sure the surface is flat, and experiment before committing.