Instructables

Custom Solid Surface Cutting Board

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This Instructable will teach you how to make a custom cutting board using solid surface material that is normally used for kitchen counter tops. Most people refer to it as corian, but corian is a brand name of solid surface material.

These custom cutting boards are great if you want something a little different for a gift or for your own use.  You can personalize them for each person.

It can be a little difficult to find solid surface material, but patience usually pays off. Check with local kitchen and bathroom installers. Sometimes they will have old stock material that isn't going to be used that they will sell cheap. Other times they will have cut-outs for sinks that can sometimes be the perfect size for cutting boards or other projects.
 
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Step 1: Materials and Tools Needed

There really aren't a lot of parts needed for making the cutting boards.

MATERIALS
  • Scrap solid surface (corian) material
  • Sand paper of varying grits. I used 150, 180, 400, 800 and 1200 grit. The 800 and 1200 grit were Wet/dry automotive sand paper.

Tools

The tools I used on the project were as follows:
  • Band saw
  • Oscillating spindle and belt sander
  • Random orbit sander
  • Router
  • Router table

NOTE: If you plan on using any tool for a project please make sure you are familiar with the tool and all of the dangers associated with it. If you are not familiar with a tool then you should ask someone who is to show you the proper way to use it. A lot of communities have classes at local colleges on the proper use of tools and machinery. There are also local woodworking clubs that offer classes at very reasonable rates for beginners. I highly recommend using these resources for your safety and for the most efficient use of the tool.

SAFETY FIRST
Always wear eye and hearing protection.
Always work safe with the proper safety equipment and guards on your tools.
SWiiiTCH1 year ago
You would also be very satisfied with the finish by using a random orbital palm sander. starting with180 grit, (100 grit first if really rough edges) then up to 280 grit. Be sure to WIPE DUST OFF PROJECT BETWEEN GRITS... Finally, with your sander, polish with a gray scotch brite, followed by a gold or white scotch brite. Also not necessary but it helps to slightly wet the scotch brite pads with soapy water. Any clear handsoap works great. wipe dry with a towel and you will be happy. It is not necessary to go beyond 280grit but you may go up to 400 grit for darker colors if you like..