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Old 01-10-2019, 10:01 AM   #1
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Replaced "WasWood" with Corian (solid surface) countertop

Last summer we had a leak at the edge of our sink, which swelled the MDF counter top. Given that FR decided we needed a large sink and very little counter space in our 2250 and the eventual leak due to FR's poor assembly practices, we decided it was time to correct the issues once and for all.


I had never worked with Corian (aka Solid Surface), but in researching, it is worked in a similar manner to fine woodworking. I decided to take on the task.


After purchasing a smaller rectangular undermount sink and acquiring the Corian at half cost from a local cabinet builder, a friend and I set about removing the old stuff:


and building up a new flip up counter as well as the main kitchen counter.


Gluing up the new countertop:





Results after routing:








Sink mounted:





With cutting board insert and original faucet:





Flip-up mounted; main top & strip to the right of the stove mounted:





Backsplash trim details:





Trim installed:






Trim detail with metal tile section that I'll be installing today:





More details on my photo website; scroll to the bottom for the countertop pics: 2016 Sunseeker Photo Gallery by BNMac at pbase.com
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Old 01-10-2019, 10:08 AM   #2
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Absolutely beautiful, well done!!


I suggest you send this to FR and show them what real quality is!!
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Old 01-10-2019, 12:48 PM   #3
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Fantastic job! Looks great!!!!
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Old 01-10-2019, 12:54 PM   #4
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Skills!
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Old 01-10-2019, 01:08 PM   #5
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Nice job thinking outside of the box and being creative. Beautiful end result.
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Old 01-10-2019, 01:11 PM   #6
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I can't figure out if you are bragging....or just that good.

HA HA just kidding. I am only jealous
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Old 01-10-2019, 01:39 PM   #7
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Very impressive. I looked at coating mine with epoxy or something. Looked like too much work so I just cover it with a black cutting board.
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Old 01-10-2019, 02:02 PM   #8
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very nice...

Thanks for sharing the photos
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Old 01-10-2019, 02:31 PM   #9
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Awesome job! We have been researching countertops for kitchen and baths and have almost decided on Solid Surface ones.
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Old 01-10-2019, 03:45 PM   #10
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Thanks everyone!

Other than the expense, solid surface is the way to go. Depending on pattern, a sheet of 3'x6' can range up to $500. I purchased two remnants that will be more than sufficient for the kitchen, dinette table and bathroom vanity for a little more than half of that amount.

While researching this project, I found it's unlikely a cabinet shop will take on this type of job on an RV. The shop where I purchased the material would not take it on, as they had tried once before and found the supporting cabinets to be substandard construction and "out of square". I have no idea what type & size of RV, but the lead was adamant - they would not do the job. Initially, I thought I'd be able to submit plans and have them make the pieces, but not have them install them. They wouldn't even entertain that idea. After 15 minutes of discussing the issue, I was finally able to persuade him that, in the end, I had decided all I wanted to do was purchase the material and do all the work myself. He was then more than happy to sell me the raw material.


Rather than use the colored epoxies, I chose standard "off the shelf" 5 minutes epoxy from my local big box store for the build-ups. Very little is needed and the quick setup time lends well to gluing up a piece, then machining it within an hour.


I'll continue to post to this thread when I complete the kitchen, dinette table and bathroom vanity. I also have some other mods underway that I'll post as well.
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Old 01-10-2019, 03:48 PM   #11
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That looks great!
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Old 01-10-2019, 06:25 PM   #12
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Skills!
Mad skilz! LOL.

Great job, Bruce. I can't wait to see the rest.
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Old 01-10-2019, 06:52 PM   #13
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Very nice, well done! Thanks for sharing this. It is very timely, as I have been contemplating similiar for my bathroom.

Mine is MDF as well, but has yet to fail as I had replaced the short, too close to the back edge of the sink faucet with a medium rise that goes further out over the sink.
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Old 01-10-2019, 06:55 PM   #14
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Questions concerning using Corian

I was really glad to see your post on redoing your counter top with Corian. I am going to add a Washer/dryer combo to our Flagstaff 5th wheeler and have decided that the best place to put it is under the cabinet in the kitchen. We have Corian and so my concern has been how hard is it to work with. I have done woodworking for most of my life but have never worked with Corian. Any advise would be greatly appreciated.
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Old 01-10-2019, 07:24 PM   #15
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Beautiful job, like others, I am envious of your skill!
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Old 01-10-2019, 07:43 PM   #16
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Originally Posted by laneb52 View Post
I was really glad to see your post on redoing your counter top with Corian. I am going to add a Washer/dryer combo to our Flagstaff 5th wheeler and have decided that the best place to put it is under the cabinet in the kitchen. We have Corian and so my concern has been how hard is it to work with. I have done woodworking for most of my life but have never worked with Corian. Any advise would be greatly appreciated.

Lane, Start by downloading the plethora of documenation from DuPont's Corian website:
Documentation - Corian® solid surfaces, Corian®

Search for fabrication_manual_pdfs-2.zip, which will take you to the Corian website.

Router bits should be carbide, and sharp. If you don't already have a 1/2" router, you can do the majority with a 1/4". My Porter-Cable has both 1/2" and 1/4" collets, of which I used both. All router bits must have bearings if it has a guide pin.

Your table saw blade should be a -5 to +10 degree hook, triple grind:



(Look up a triple grind teeth if you are not familiar with the term)

I have the triple grind with a 0 degree hook, and it works beautifully in corian, aluminum and wood.

Otherwise, experiment on scrap, then have fun. Corian is precise material - it dimensionally stable. There's no grain, so it works well in any direction.

I use standard 5 minute Devcon epoxy. Spread it very thin, then use a lot of clamps. Your pieces will want to creep, so pay attention. Use denatured alcohol for cleanup before it sets.

Corian/solid surface works a lot like a hard hardwood, such as maple or zebrawood, for example.

Enjoy!
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Old 01-11-2019, 10:45 AM   #17
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Very nice work.
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Old 01-11-2019, 05:58 PM   #18
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I used to fabricate Corian countertops. Great stuff except for the dust when working it. It was the reason I got out of the cabinetmaker business.
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Old 01-11-2019, 06:21 PM   #19
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That is a great idea and some very nice work. I definitely want to see how the dinette and vanity come out. We have the same MH, just a 2012, and I recently put this dinette table together. It is from ripped down hickory flooring that I glued up.
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Old 01-11-2019, 08:51 PM   #20
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Nice loooking table, too!
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