Modifying a Corian kitchen counter top

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Forum topic by Mainiac Matt posted 10-19-2018 06:05 PM 542 views 0 times favorited 5 replies Add to Favorites Watch
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Mainiac Matt

9607 posts in 3139 days

10-19-2018 06:05 PM

Topic tags/keywords: cutting corian

I have a Corian counter top on 30” deep base cabs in my kitchen, so I have a slide-in gas stove/oven (i.e. no back panel like a free standing oven and not quite as deep).

The oven is 22 years old and recently crapped the bed. When we estimated the cost of repair, we decided that it didn’t owe us anything and it didn’t make sense to pump money into an oven this old (it’s “well worn” with rust around the door glass frame, scratches and stains). But we were surprised to find that all of the major appliance manufacturer’s have changed their form factor for slid-in ovens to make them interchangeable with free standing ovens.

So I need to modify the deep ‘U’ cut in the Corian counter top, to make it ~2” deeper. Fortunately most of the cut edge will not be exposed, so I don’t think I have to get to crazy about the sanding and finishing of the edge after I cut it. But I am going to have to do this in place.

I’m thinking about clamping guide boards to the top of the counter and using a router to make the cut in several light passes.

Anyone ever done something like this before?

Does this sound like a sound plan?

Anything special required for the router bit?

Thanks in advance for any good advice….

-- Matt -- I yam what I yam and that's all what I yam

5 replies so far

View lumbering_on's profile


578 posts in 1301 days

#1 posted 10-19-2018 06:19 PM

It sounds like a workable plan, but I’d want to contact a Corian seller to ask about the router bit. You can cut Corian with a normal wood blade, but I’d think that routing would be a bit of a different story.

View 000's profile


2859 posts in 1710 days

#2 posted 10-19-2018 06:19 PM

Your on the right track.
Normal Flush trim router bit works. I believe 4 flute bits are recommended but I have done plenty with 2 and 3 flute bits. Just sand ALL the edges and break the top and bottom of the edges.
This is where fracture cracks start.

RE: Fracture cracks, this is why a router is best, jig saws leave small fractures, it’s ok if you sand them all the way smooth. but the fractures can run deep into the edge of the material and when you have expansion and contraction they can lead to a crack in the top.

I doubt your edges get hot, but when whenever I cut out for a cooktop I wrap the edges with foil heat tape.

EDIT: Make a tent, you will have snow everywhere!

View Fred Hargis's profile

Fred Hargis

6327 posts in 3304 days

#3 posted 10-19-2018 06:39 PM

My experience is limited to having the Corian installed when we remodeled our kitchen some years ago. What I saw was they trimmed and worked the Corian with carbide router bits. The told me pretty much the same thing jbay said about the fracture cracks, you want to make sure there are none. They also trimmed the edges of the cooktop cut out with foil tape as jbay described. The explained why, and it made no sense at all (something about Corian not being a “heat sink”; so I guessed they were trained to do the foil tape and forgot the real reason.

-- Our village hasn't lost it's idiot, he was elected to congress.

View Heyoka's profile


58 posts in 663 days

#4 posted 10-22-2018 04:21 AM

In the cabinet shop I used to work at we did lots of solid surface material. Always cut wth a router, never heard of using foil tape at all….

-- Heyoka

View waho6o9's profile


8921 posts in 3388 days

#5 posted 10-22-2018 02:38 PM

I asked the Corian installer what to use to cut Corian when they installed our counter tops and carbide
was the answer.

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