Plunge cutting into formica

[Kevin]

I want to plunge into a formica counter top to do an inlay and I'm wondering what the best router bit would be for that purpose.
The critical cut will be the edge cut, I'm not concerned about cleaning out the center once the outline is routered in.

[pigman]

Carbide down cutting spiral bit.

[Kevin]

That's what I was leaning towards.
It should be good on the plunge but how do you think it will cut lengthwise along the edge?

This is what the manufacturer says about them...

Will plunge cut and plane edges. Eliminates chipping at the top of the cut. Ideal for soft & hard woods, plywoods & composites, laminates, plastics and some non-ferrous metals.

[tyb525]

That should do well. The down cut spiral bits are designed for what you are wanting to do, make a clean top edge cut, especially in veneered material.

[SPIKER]

Thoughts on using some good tape to keep chipping&  splintering down would be nice.  I was watching and looking for answers on my own for similar projects that will be coming up in near future.

Thanks
Mark

[tyb525]

By nature, down cut bits won't splinter, because the wood fibers are being cut downwards, or into the wood. The drawback is less effective chip removal, but several shallow cuts should reduce the problem.

[Kevin]

Right on.
I have a burn in a counter top from a hot pot so my intention is to cut out a section and inlay it with tile.
I just have to find a tile now that isn't prone to chipping, any ideas on that? ???
The bits are on order.

[terrifictimbersllc]

I just plunged a regular 5/16" dia carbide straight bit into my saw table extension, laminated with formica, in order to inlay a miter track near my router plate insert.  There was no chipping and the line was perfect except at one end where i wasn't careful and let it wobble.  Can post a picture later. I used my t-square fence as a guide for the router.

[Kevin]

I'm going to pick out the tile , get a measurement then build a square frame to run the router around inside.
I'll try double face tape to hold the jig in place.

[Don_Papenburg]

I would also put a couple of sticks over the template clamped to the counter edge with parralel jaw clamps .  That helps to keep templates in place .

[Radar67]

I've always scribed the line on any laminate work to ensure that there is no chip out.

[Warbird]

By nature, down cut bits won't splinter, because the wood fibers are being cut downwards, or into the wood. The drawback is less effective chip removal, but several shallow cuts should reduce the problem.

Agreed on the shallow cuts.  If you try too deep of a cut and put too much perpendicular force on the bit while making the lengthwise cut, you could break the bit.  Happened to me when routing out some bamboo for our window bench.

[Kevin]

I had a second thought on holding the template, I can screw it to the counter top and rout around the edge of it then remove the screws and template then rout out the inards.
I'll just have to be extra careful going around the corners.
I will use tape but I don't think I'll be able to get an exact, perfect scribe for the router bit to follow.
If it doesn't work out I just replace the counter top, it's just over the dish washer.

[Kevin]

I'm almost psyched up for this event, the remaining question is which direction of travel with the router around the template or guide board?
I'm thinking counterclockwise but need a second opinion.

Thanks.

[beenthere]

Kevin
If me, I'd make the reverse pattern for the guide. I would have the fear that the bit would climb away from the pattern you have and spoil the plan. If following an outside pattern, any cleanup due to bit pulling would be easier and without enlarging the inset size.

Practice your plan by using what you have to make a cutout in a larger piece of plywood (or formica top if you have it) to satisfy yourself which direction.

Also, I might make a smaller inside pattern to help support the router shoe so the router cannot tip while cutting. Hope that makes sense.

[blaze83]

the only other thing i would do a bit differently is this. I would make my initial cut an eith to 3 sixteenths inside where your finish cut will be, then come along and clean up the edge to the desired dimensions, this way if ther is a wobble or a chip, you can clean it up .

just my 2 cents

steve

[Busy Beaver Lumber]

Kevin

Rather than inlay it with individual tiles and have to worry about bacteria buildup in the grout or staining of the grout, how about going to a countertop maker that works with stone and have him make you a perfect fit inlay out of a piece of polished granite or corian?

A friend of mine actually built an oak dining room table with 4 granite inlays in the center of the table so his wife could bring hots pots and pyrex glassware from the kitchen and put them right on the granite inlays in the table without having to worry about damaging the table. Looked great and worked out very well

[Kevin]

I wasn't trying to enhance the counter top but rather making do with what's there so I don't have to pull the dishwasher out to replace the top.
This seems to be the easy solution.
The tile is mosaic so if a line gets messed up I can just open up the width to accommodate another row of tiles but it should work the first time around if I keep constant pressure against the plywood.
If it doesn't work then I'll be replacing the counter top which I would have done any way.

Thanks for the input.

[Kevin]

My blood pressure is back to normal.  ;D

[pigman]

That looks good Kevin. 8)
See, that wasn't so hard afer all.  :D

[Kevin]

I have to admit, it looks better than the pot burn.

[SwampDonkey]

Looks real good to me Kevin. 

[Jeff]

That really looks good!

[SwampDonkey]

I'm thinking of doing some counter top here this summer. If I get around to it. ;D Going to paint the kitchen to. Not a lot of wall to paint because it's mostly cupboards.

[metalspinner]

That looks great, Kevin!