Extreme Fabrication With Corian™ Solid Surface

I built this piece for a local children's hospital

Step 1: Solid Foundation

first - start with some well built casework. make whatever shape you like. The better you make your casework- the less work you'll have to do later .I flipped this piece on its side to let gravity work for me in my next step...., thermoforming

Step 2: Thermoforming

with the luxury of a LARGE oven, I wrapped this with about six separate pieces. keep it flat to the casework! a bit of creativity, a lot of determination, mirror cutting my seams, and endless brainstorming helped me get through it in about 36 hours overall.

Step 3: Attach As You Go

with about 5 tubes of silicone, some straight edges, and a boatload of clamps on hand, I started at on end and worked my way around attaching to the casework and seaming my pieces together as I went

Step 4: Time for the Top!

After making a template of the upper part, I seamed a deck piece to the apron and casework. flush trimmed the excess and belt sanded my seams smooth as butter..,

Step 5: Finishing

now i sanded out my belt scratches with a 5" random orbit dual action palm sander, and for some parts a 12" GEM sander, beginning with 180 grit then with 220, to 400 grit sandpaper. I finished it off for that showroom shine with some soapy water and a gray scotch-brite on my sanders. VIOLA! You can now experiment with your own stuff, but I recommend starting a bit smaller. this is my woodworking and countertop EXTREME FABRICATION INSTRUCTABLE!!!!! Thanks!