Kitchen Remodel #9: The Corian installation continues.

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Blog entry by Karson posted 11-03-2008 01:57 AM 9283 reads 1 time favorited 13 comments Add to Favorites Watch
« Part 8: My first try at Corian Part 9 of Kitchen Remodel series Part 10: The Corian installation continues #3. »

Before we get started, I stated in the previous blog that I’d let you see the cement tube that is used to bond the Corian pieces together.

The glue tube with two separate compartments, One for the fill material and the second for the catalyst. The plunger is part of the adapter kit that allows it to be used in a regular caulking gun. Your option is this, or a $80.00 to $150.00 gun. I opted for the $4.00 part.

The small plastic piece beside it is an adapter that allows it to be used in a regular caulking gun.

Somewhere in my pressing the plunger i split the plastic piece so I wrapped it with Duck Tape. A real redneck thing to do.

The tip that is attached to the front of the cement cylinder has a waffle pattern that mixes the two products together.

Now on to today’s entry.

I took a piece of Corian and brought it into the house to sit on top of the base cabinets so my wife would have some place to put things.

She said that she wanted a rounded end. So i took a pencil and drew the curve on the end of the Corian. I took a jig saw and cut it off.

I said is this what you want. She replied yes.

I made a 1/4” mdf pattern of the curve and sanded it smooth so that it would be a router template to put the edge on the Corian.

So I cut the edge with a jig saw to within 1/8” of the line and then I used the router template to cut the edge of the top piece of Corian.

I then started cutting small pieces to make the edge.

Then sense kicked in and I figured out that I didn’t want to glue in all of those small pieces.

So I glued on a big rectangle piece on the end, and the edge banding around the edges.

I then started on the smaller piece of Corian that would be attached to the large surface. Drew my line.

Started to cut it with a Ryobi Lithium Battery skill saw.

The blade is quite thin and cuts a great cut to break down the Corian into manageable sizes. This is what I used at the salvage depot when I bought the Corian.

I then cut it on my table saw to 25 1/2” square.

Getting ready to glue the edges on the small piece but I also needed to make a gluing brace to join the two pieces of Corian together. This is a chunk of Corian the goes across the seam so that both surfaces will be glued to it. Here I’m glueing it to the large counter top.

Now the for real glueing. I found out that you need to practice the glueing process before you open the cement, because that is not the time to go get the clamps that you need. My practice run noticed that I was tipping the Corian glue brace and I needed a better bonding clamp. Therefore I used Bessie clamps.

I then glued the edges on the small piece.

I only need edges on two sides. I don’t need any on the back nor on the side that is attached to the large counter top.

While the glue was setting up I started to work the edges on the large surface that was glued up last night.

I turned it over and this is the view of the large pieces that i glued on the edge.

I cut to within 1/8” with the jig saw.

I then used the router to trim up the lower pieces to match the previous cut edge.

It was at this point that Greg3G showed up with his wife from W. Virginia. So we had a little visit. After he left I didn’t take any more pictures but what I did was clean up all of the edges by using a piece of 1/4” Corian as a straight edge and used a pattern router bit to clean up all of the edges instead of using a belt sander. It’s faster with a router. I also used the MDF pattern of the end and trimmed it back another 1/16” to clean up some glue. Hand sanded the edges with 100 grit sandpaper to get rid of any router divots.

I then carried it into the house to see how it fit in its intended spot. The two pieces are not glued together yet.

The edges are still square and have not had the rounder over edge put on it. I’ll wait until the two pieces are glued together so that the final edge cuts can be made. The mating edges where they need to be jointed are a perfect fit. It should be able to come together with no visible seam.

That’s tomorrows work.

I bought 4 tubes of glue, I’ve used 3 so I will need somemore. The tips are a throw away piece, because once its been used, you can’t clean out the glue. You throw it away and start with a new tip. I got 1 tips with each tube. I bought 4 extra. So my tip supply is good for now. You get all the pieces that need glue ready, before you start. You don’t say I’ll glue these up and then get these ready to glue later. The tube can be resealed so you don’t lose the rest of the tube, just the tip, $1.50 each.

One thing that Lee Jesberger told me is this stuff is messy. He is right. Dust everywhere in the shop from the table saw cutting. Everything else has been done outside on sawhorses. and there is non-biodegradable plastic everywhere.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

13 comments so far

View lew's profile


12821 posts in 4206 days

#1 posted 11-03-2008 02:06 AM


Really looking good! Thanks for all of the helpful information.

How did you learn to work with the Corian? Is there a web site or DVD that provides information?


-- Lew- Time traveler. Purveyor of the Universe's finest custom rolling pins.

View Grumpy's profile


25526 posts in 4302 days

#2 posted 11-03-2008 02:09 AM

Great blog Karson. The cabinet is coming along well. I like that cordless saw.

-- Grumpy - "Always look on the bright side of life"- Monty Python

View Les Hastings's profile

Les Hastings

1305 posts in 4224 days

#3 posted 11-03-2008 02:19 AM

Looks like your gettin it done Karson! Doing a great job, Enjoyed the blog. Thanks for the post.

-- Les, Wichita, Ks. (I'd rather be covered in saw dust!)

View Bob #2's profile

Bob #2

3810 posts in 4472 days

#4 posted 11-03-2008 02:21 AM

You really have nerves of steel Karson.
A mistake with this material and it’s coal in your sock at X-mas.
Nice job! -
Shows off your years of experience very well.


-- A mind, like a home, is furnished by its owner

View Todd A. Clippinger's profile

Todd A. Clippinger

8901 posts in 4550 days

#5 posted 11-03-2008 02:40 AM

It looks like you’ve gone pro!

-- Todd A. Clippinger, Montana,

View Karson's profile


35194 posts in 4851 days

#6 posted 11-03-2008 02:52 AM

I found one web site that had a few paragraphs on how to work with this stuff. Everything else is using wood techniques on some plastic. No classes, I figure that this stuff is repairable. I’ve got one void where two pieces didn’t come together when I was putting on the edge. It’s a 1/8” void.

I’ll make a tapered piece and then next time I’ve got the glue open, I’ll drive it into place and then clean up the edge by hand.

I have worked with plastic before. I took a course in college that was some plastic, and graphic arts. So I’ve done some plastic work about 48 years ago. So finishing and polishing are a couple of technques that I’ve tried before. But, Corian this is the first time.

Besides that I’m cheap. Anything that I can do myself and not have to bring in “An Expert” is the way I go. If I fail then I’ll go with the expert. Haven’t had to do that yet. So welding, wood work, decks, kitchen cabinets, counter tops. Try it, before you hire someone else to do it.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View jim1953's profile


2737 posts in 4293 days

#7 posted 11-03-2008 02:58 AM

Looking Good Keep It Up

-- Jim, Kentucky

View Greg3G's profile


815 posts in 4536 days

#8 posted 11-03-2008 03:02 AM

I took the afternoon and drove out to see Karson today. I needed some more 1/4 ambrosa stock and my bandsaw was giving me fits. When I turned into the drive to Karson’s workshop, there he was, covered head to toe in Corian dust. I had brought my wife along and after introductions and a warm greeting, Karson gave us a tour of the progress of his kitchen remodel. I must say, the pictures he has posted doesn’t due justice to them. The design and wood selection is outstanding. I was having a hard time describing the design to my wife. Now thanks to Karson, it looks like I may be starting a new set of cabinets soon. We stayed maybe an hour or so…Karson even shared some persimions from the trees out behind the Guild’s toy shop. It was my wife’s first time to taste them and she loved them. All in all, we had a great time with Karson and his wife. The kitchen is coming along well and I have every confidence that he will meet the Mother-in-Law deadline. Thanks again Karson, we’ll see you again soon.

-- Greg - Charles Town, WV

View Karson's profile


35194 posts in 4851 days

#9 posted 11-03-2008 03:26 AM

Greg my wife said that she had a good time talking with your wife, while we were wood shopping. Glad you made it down again. I’ll have to recipiate it sometime.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Appomattox Virginia [email protected]

View Lee A. Jesberger's profile

Lee A. Jesberger

6866 posts in 4430 days

#10 posted 11-03-2008 05:32 AM

Hi Karson;

Looks like things are coming along nicely!

I’m anxious to see it completed almost as much as you!


-- by Lee A. Jesberger

View lightweightladylefty's profile


3367 posts in 4163 days

#11 posted 11-03-2008 09:08 AM


It certainly is generous of you to share your expertise with all of us. You’re living proof that being cheap—frugality sounds a little nicer :-)—is really an asset! It has taught me much of what I know, too!

-- Jesus is the ONLY reason for ANY season.

View sandhill's profile


2128 posts in 4375 days

#12 posted 02-13-2009 07:24 AM

I have to say I think I will pay the instal priceand stick with woodworking. Your a real brave man, looks good though to take on that kind of project.

View Jacqueline's profile


14 posts in 2890 days

#13 posted 04-05-2013 02:01 PM

Hi Karson, I just found your post because we, too, happened upon several great pieces of Corian we are going to incorporate into our ongoing house remodel. $1 per square foot, but how to do it?! Found your post and was just what I needed- will be sharing with the husband- we’ll be getting starting this weekend on a two week push over “vacation.” Thanks for the great specifics!

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