Kitchen Remodel #13: Finishing the Corian, I wish.

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Blog entry by Karson posted 11-12-2008 02:10 AM 6024 reads 2 times favorited 17 comments Add to Favorites Watch
« Part 12: More Corian work. And, yes Todd was right it is just like glass Part 13 of Kitchen Remodel series Part 14: The Veneering gets going again »

After I got the counter top in I did the thing which makes your heart beat fast. I cut a hole in the top of the sink.

It was planned, but it doesn’t make it any easier.

Once that hole is there, there is no going back.

So for the next 3 hours, I put in the faucet.

Hooked up the new Dish Washer.

And put in the cabinet that will hold the trash containers.

And what do you get. A plumbing nightmare. The drains from the two sinks are at a different height. and are a different height from the original sink. The water line for the dishwasher wouldn’t fit so a new flexible hose was used. The drain line for the dish washer was too short to fit the fitting on the disposal. So the disposal had to be turned 90 deg. and then all of the waste lines had to be put together.

I was only able to make everything fit by using 2 flexible drain pipes. Of course the hot and cold water lines had to be replaced for the sink because they were all different lengths.

So here is the view. Only use one eye.

So that was all last night. I went to bed tired. I got up this morning with my wife telling me that she doesn’t like the new faucet. Of course the hole is already there. Our options are cut down. She wanted a higher /taller faucet. I knew she did, and I was surprised when she picked the one that she did. Maybe she was going for the price!

She went to the store and I went outside to work on the last piece of Corian. This will be the return that goes over the dishwasher.

It’s small 43” X 25 1/2”. The only thing that is a little different from the one that was removed is it’s longer, because my base cabinets are 4” longer.

This is the space cadet that has been doing all of the work. Hearing protection, Dust protection, Safety glasses and a full Tyvek Haz-Mat suit. It was 32 deg this morning in the driveway and the Tyvek suit keeps me warm. I’d hate to use it during the summer.

First I trim off the lower pieces to be flush with the top surface. I use a pattern router bit with the bearing on the top.

I trim off the support pieces that level up the Corian top to the cabinets.

I then do all of the Ogee profile, sand it and polish it and bring it into the house.

Visible is the glue block that supports the glue line and bonds the two separate pieces together.

Also visible is the wooden blocks that I’ve put on the surface with hot melt glue. I put a square against the wall so that all of the blocks would be straight in line with the glue line and each other.

I spread the glue and slid the return piece into position. And I put on the clamps.

You can see the glue squeeze out that is required. This is not woodworking. You want the squeeze out that that tells you the the seam is not glue starved.

You let everything harden, about 2 hours. I take off the clamps.

I sand the seam with 80 grit, 220 grit, and wet/dry Abalon sheets at 360, 500, 1000 and 2000. The Abalon sheets were used with soapy water.

I did a little fancy routing and I had to cut into the molding so that the Corian top would fit in.

We bought the new faucet so I guess I’ll go now and complete it.

Tomorrow is Mother-in-law day so I’ll be offline for about a week.

Have a great week.

Back again. I got the new faucet installed. it wasn’t too bad, same MFG. but a couple of different connections.

I’m telling my mother-in-law that we are going for the new open look, so you can always see what is in the cabinets. She might accept that. I know my wife won’t.

-- 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]

17 comments so far

View ZachM's profile


83 posts in 4152 days

#1 posted 11-12-2008 02:33 AM

Looks nice. That flexible tubing wouldn’t work for me though, I push so much food down the drain i know stuff would get stuck.

Was it hard to get the corian, i though it was only sold to counter top dealers directly, or is that not true?

View Dennis Zongker's profile

Dennis Zongker

2789 posts in 4039 days

#2 posted 11-12-2008 02:39 AM

WOW! Great Blog Karson. Thats for posting.

-- Dennis Zongker

View Karson's profile


35194 posts in 4848 days

#3 posted 11-12-2008 03:33 AM

Thanks guys. We are on a septic system and I won’t let my wife use the garbage disposal. But she said it’s needed for resale. I was going to leave it out.

ZachM I mentioned in one of the earlier blogs on the Corian that I bought this stuff at a DuPont Salvage depot. DuPont’s headquarters are in Delaware and all of their salvage stuff and plants parts, fans, desks are sold in this outlet.

They also carry 15 different kinds of Corian. 7 kinds at $80.00 a sheet 12’ X 30” or 30 Sq Ft. and 8 kinds at $135.00 a sheet. The higher priced ones are more of a premium grade. The have some sinks (This is one of them) and a bunch of bathroom vanity now. When they get low they call and they send another truck load. They never know what they’ll get. They had a few laptops the last time I was there for $200.00 so you never know. But, it’s 85 miles from me.

There is an advertiser on LumberJocks that sells Corian and other solid surface materials. So it’s not limited any more. But, they don’t sell it at Big orange or big blue. Even though the color that we selected was Fog that was made for Lowes and only sold by Lowes installers. It’s now a discontinued color.

I found it on Craigs List and kept the phone # for about 6 months until I started the kitchen project and we went up and made our selection. We went for the $80.00 version but when I went back 2 weeks later they had some at the $135.00 price which I believe my wife would have jumped at. It was a mother of pearl style.

I have seen Corian installers there and they are going to make a killing on the price over what they’d have to pay wholesale.

-- 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 Grumpy's profile


25523 posts in 4298 days

#4 posted 11-12-2008 04:20 AM

32 deg here too Karson but thats F. Just as well it’s heading to winter with that gear on. Great post on the kitchen, looks like things are coming to a close.

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

View teenagewoodworker's profile


2727 posts in 4215 days

#5 posted 11-12-2008 04:22 AM

wow, that must have been some really fun plumbing to do! lol!

View lew's profile


12821 posts in 4203 days

#6 posted 11-12-2008 04:42 AM

Karson, buddy, you deserve a medal!! All this for a Mother-in-law visit!

The most my wife ever made me do was change all of the door knobs and hinges because they were no longer shiny.


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

View Karson's profile


35194 posts in 4848 days

#7 posted 11-12-2008 04:52 AM

Lew: I didn’t do this for the mother-in-law visit, But I did want to get all of the base cabinets installed and with the counter top.

The drawers are hard to open because there are no knobs on them. maybe I’ll do that tomorrow morning. My wife is now leaving all of the drawers open so they are easier to open.

They are a self closing version so they are hard for the first 2 inches.

-- 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 itsme_timd's profile


690 posts in 4278 days

#8 posted 11-12-2008 05:43 AM

This is looking great Karson, I’ll need to keep these notes for when I do my kitchen upgrade. Plus – I get to look forward to the cool outfit! ;-) Enjoy the mother-in-law time.

-- Tim D. - Woodstock, GA

View Lee A. Jesberger's profile

Lee A. Jesberger

6866 posts in 4427 days

#9 posted 11-12-2008 05:51 AM

Hi Karson,

Nice suit!

The corian work looks like you’ve been doing it for years!.

Those flexible parts on your drain line may give you some problems, since you have a garbage disposal. The “ribs” have a tendency to catch debris. Let’s hope for the best on that.


-- by Lee A. Jesberger

View Karson's profile


35194 posts in 4848 days

#10 posted 11-12-2008 06:06 AM

Thanks for the comments on the flex pipe. I’ll redesign using some solid pipe. But like i said the disposal is not used by us except for the water dump for the dish washer.

-- 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 Grant Davis's profile

Grant Davis

804 posts in 4355 days

#11 posted 11-12-2008 03:08 PM

I am loving this blog that you are doing. I was showing SWMBO the Corian coutners and it now looks like that is what she has planned for me when I redo our kitchen.

If I may ask, what kind of sink is that? I love the little piece on the side.

-- Grant...."GO BUCKEYES"

View Karson's profile


35194 posts in 4848 days

#12 posted 11-12-2008 03:35 PM

The sink is a Corian sink. We just happened to find it at the outlet. If we hadn’t flound it then I’d probably just do the pattern using a plunge router and cut the groves into the Corian.

I would make a tapered ramp that goes downhill to the sink and as the router goes down the ramp it would cut a deeper and deeper groove. It would be like cutting flutes in a column.

You could make just one flute in your pattern and keep glueing the mold on with hot melt glue. It really sticks well and you have to whack it to get it to free up.

I’m glad that I’m helping others to see some options. on counter tops.

The homemaker/handyman/LumberJock can try lots of things that you might not want to pay someone else to do. Their labor rate is probably higher than what you calculate for your time.

-- 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 Todd A. Clippinger's profile

Todd A. Clippinger

8901 posts in 4547 days

#13 posted 11-13-2008 02:54 AM


As a professional remodeler I would say get a pro plumber in to straighten out your plumbing. I have seen a lot over the years and that looks like trouble waiting to happen. You have definitely saved enough so far to get a plumber in on that.

At this point the access is very good and it will cost less to have the work done properly and avoid any damage that may occur from failure in the future.

It is a misconception about garbage disposals being bad for the septic system. A healthy septic system can handle it just fine.

One of the worst things for an appliance like the garbage disposal, is to not use it. They actually function better for longer if they are used. Pasta is the worst thing to put in them as it just gums up, but in general there is no problem with using the disposal on a septic system.

-- Todd A. Clippinger, Montana,

View Thos. Angle's profile

Thos. Angle

4444 posts in 4410 days

#14 posted 11-13-2008 03:07 AM

Thanks, Karson. I just wanted to let you know I’d been here.

-- Thos. Angle, Jordan Valley, Oregon

View cabinetmaster's profile


10874 posts in 4005 days

#15 posted 11-13-2008 05:09 PM

Karson, That is a great job you are doing there. Does this place ship out of their outlet store? I am planning a kitchen remodel and I would sure love to do the corian thing myself. It looks like it could be simple enough for me to handle.

-- Jerry--A man can never have enough tools or clamps

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