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This job presented several challenges. Due to it's length [12'], and relatively complex layout, I made templates and took them back to the job site to determine if they would fit correctly. There were two modifications that had to be made.
This top is comprised of three pieces, the top and two lower counters. One of the lower counters had to be cut for a small bar sink. All the edges represented angles, nothing square! Thanks to CAD, I was able to get all the sides to align properly.
The client also wanted the outer edge "corners" to be rounded. This meant that the Formica had to be bent around these curves. Not having a heat gun, a hair dryer was used and it wasn't too effective but we [my wife] managed to get it bent.
Another issue was cutting an inside cut on a 12' long piece of Formica. Not an easy task. We broke two before we finally got it. At $80 a sheet, it hurt the bottom line!
Transporting this top wasn't particularly easy either. Since the top was so long, it wanted to rack or flex. We were scared to death the top would crack before we got it to it's final resting place. All went well.
The client was very pleased with the results.
 Template |
 Stiffeners Installed |
 Heating Edge |
 Installing Edge |
 Sink top |
 Finished |
 Lower Counters |
 Beer? |