I've got a 3 x 3 foot sheet of formica that I'd like to use for wing templates. I've found that sanding it is so hard, I'd like to start off with a strip of formica that's close to the width of my template outline to minimize the sanding.

What's a good way to cut strips of formica? I tried scoring with a blade and a straight edge and snapping, but the top portion breaks off differently than the backer board, resulting in an ugly cut, ruining the material. It seems like my razor blade can only score the top material and doesn't cut into the backer board.

I don't have a scroll saw, but I do have a dremel tool and utility knives.

Thanks for any advice.

Joel

Originally Posted by joelontheroad

I don't have a scroll saw, but I do have a dremel tool and utility knives.
Joel

You could probably do a fair job of cutting templates with a Dremel shaper/router table, item number 231 at
http://www.dremel.com/html/home_fr.html

Probably need to get the correct cutter as well.

Dremel fibre-reinforced cutting discs will cut Formica with no trouble. They do wear away fairly fast so it's not a cheap option if you're going to be cutting a lot. I used to use a fine-tooth hand saw to cut the blank and then sand from there (but a scroll saw is MUCH easier ).

Steve

I just used scissors (not the small one) for a similar material, came out very well. Once I found I can cut without breaking the material, I cut the template along the line, no sanding was needed.

-- Rajesh

cover the front and back of the formica in masking tape. Then use toothed sicsors. The masking tape prevents it cracking so much. Then just use a file to get to the correct level.

Originally Posted by mr_wood

cover the front and back of the formica in masking tape. Then use toothed sicsors. The masking tape prevents it cracking so much. Then just use a file to get to the correct level.

Intriguing idea. What are "toothed scissors?" Are they like emt shears?


Thanks everyone for the great suggestions.

Joel

These industrial quality shears cut sheet metal as well as plastic laminates. I have used these style shears for many years with great success. They cut a 1/4" of material out in a curly que fashion. It won't tear either side of the cut.

Here is a link-
http://www.route66supply.com/store/page82.html

Believe it or not tin snips work very well on plastic laminates. Keep the piece you want to save in your left hand and cut about a 1/4 " to the right side of your line then trim off the 1/4" piece to finish it off. It will create hairline cracks in the excess on the right side of the snips about a 1/4" to 1/2" long so make sure there is enough space on that side to trim off the selvage. Try it on a scrap piece....

HotRod 36