Extreme Fabrication With Corian™ Solid Surface

Introduction: 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!

Step 6: This Was My First Instructable, So Feel Free to Leave Comments at Will

please be kind, or not..... I can take it



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    11 Discussions

    That's really nice (and shiny) work! I have a bit of feedback for you on the Instructable itself (you asked for it!):

    ~ You might consider going into some more detail; giving specifics about the process; and including any tips, tricks, jigs, etc. that you use (e.g. tips for getting the pieces to line up, applying the adhesive, clamping, how best to cut the material, or whatever else you think that someone doing this for the first time might find difficult).

    ~ I would guess that most people who haven't done a counter top are unfamiliar with mirror seams, so it might be worth a brief explanation. (I'm assuming that you cut the seams before bending the pieces?).

    ~ You appear to have used a few other special techniques and materials, which people might be interested to hear more about. For instance, I would guess that a lot of people aren't familiar with flexible plywood, and might be wondering how you got that rounded profile to work! (Also, I want to see a picture of this giant oven!)

    ~ Overall, I think it would be good to add more details and explanations of particular challenges and solutions. I would suggest trying to write on the assumption that your audience is composed of laypeople. The most interesting Instructables to me are the ones that teach me about something that I'm unfamiliar with (meaning that they have to be simple enough for me to understand!).

    My suggestions aside, this is a really neat project that I found quite interesting. Thanks for sharing it, and welcome to Instructables. I hope to see more of your projects in the future!

    1 reply

    thank you for the feedback. I'll definitely keep that in mind when I remember to take progress pics of another project. I usually only remember to snap a shot when its finished....??. here is a stock photo of the oven you wanted, unfortunately after 11 years, I had to leave the solid surface company, due to the fact that a $0.19 cent pay increase i was given after waiting through a 5 year "wage freeze" due to "the economy" was absolutely insulting and unacceptable to me and to the quality of work I put out. Bitter? maybe. hurt? yes.


    Very cool! It's always fun to see these extreme projects that I'll probably never have a chance to make but it's amazing to see the process and work that goes in!

    1 reply

    That finished counter must weigh a ton! What temperature is the oven heated to make the Corian pliable? I guess that unless you are factory certified, the common person will not be able to buy blank sheets of the material or even get hold of the excess cutoffs for use.

    4 replies

    it did weigh a crapload. i needed 4 other people to help me lift it onto a pallet for transport lol. i usually heat the oven to around ~ 350°F and, depending on the size of your piece, for anywhere from 5-20 minutes. and also there is actually a few places that anyone can purchase the materials as well as the color matched adhesives. one of them is solidsurface.com. but you may be able to sweet talk your local fabrication shop into giving a few scraps. ;)

    i believe your ASE/metric conversion is absolutely correct. too damn much either way to me. haha

    Things are all well and good when you get volunteered to help do some moving until someone shouts "Hernia!"