Sink and Lavatory

Sink and Lavatory
C
O
SINK
R
AND
I
A
LAVATORY INSTALLATION GUIDE
N
®
This guide describes how to install sinks and lavatories in
countertops and vanities of DuPont CORIAN ®. For fabrication
information, including safe practices, recommended tools and
procedures, please refer to the Fabrication Manual,
C956-H71343.
The information in this guide is given by DuPont free of charge.
It is intended for professional use by installers of CORIAN ®. The
procedures described herein have been shown to be appropriate
for the applications described; however, no warranty, expressed
or implied, is intended or given. Moreover, the user of this guide
is cautioned to be familiar with and to adhere to manufacturers’
operating instructions, especially those relating to safety, usage
and limitations, for tools and other appliances used in the installation and fabrication of CORIAN ®. In addition, the user is urged
to become familiar with and adhere to all applicable local, state
and federal health and safety regulations.
References to products not made by DuPont suggests neither
endorsement of said products nor unsuitability of other products.
CORIAN® is a DuPont registered trademark for its surfacing
material. Only DuPont makes CORIAN®.
Copyright 1997 by DuPont, Wilmington, Delaware 19898
Contents
3
4
Introduction
5
Safety
6
Designing with CORIAN®
8
General Guidelines
Checking for Color Match
Locating Cutouts
Supporting Cutouts
Locating Faucets
Designing Multi-Bowl Installations
9
Templates, Tooling and Accessories
Using Templates
Selecting Tooling and Accessories
10
Installing Self-Rimming Sinks and Lavatories
11
Fabricating and Installing
Bevel Mount (“A”) Sinks and Lavatories
Flush-Mounting Sinks or Lavatories
Recess-Mounting Sinks or Lavatories
13
Fabricating and Installing Traditional
Undermount Sinks and Lavatories
Fabricating and Installing
Undermount Kitchen Sinks
Fabricating and Installing
Undermount Bar/Vanity Sinks and Lavatories
17
Fabricating and Installing
Seamed Undermount (“S”) Sinks and Lavatories
Constructing a Bowl Cutout Template
Fabricating and Installing Seamed Undermounts
20
Routing Drainboards into CORIAN® Countertops
Selecting a Design
Making Templates
Fabricating Drainboards
Routing the Interior
Finishing
Introduction
CORIAN® is a solid material. CORIAN® is neither
coated nor laminated; its color, texture and
pattern run all the way through the material.
About This Guide
This guide contains instructions and ideas for
fabricating and installing sinks and lavatories
of CORIAN®, including:
• Bevel (“A”) mount (flush or stepdown)
• Traditional undermount,
• Seamed (“S”) undermount and
• Self-rimming.
Combining the best qualities of wood and
man-made building materials, CORIAN®
offers unusual workability with distinctive
design versatility.
CORIAN® can be cut, shaped, edged, routed,
drilled and sanded to create customized designs.
It can also be molded into sinks and lavatories.
It also lists recommended templates, tooling and
accessories, and suggests a procedure for routing
custom-designed drainboards in CORIAN® countertops. In addition, in this guide you will see ideas
for combining, sculpting and detailing sinks,
lavatories and countertops of CORIAN® to create
unique work surfaces.
Its hard, nonporous surface is stain-resistant,
exceptionally durable and repairable, and can be
cleaned easily with abrasive cleansers.
Bevel Mount
Seamed Undermount
Self-Rimming
4
Stepdown Bevel Mount
Traditional Undermount
Safety
and industrial hygiene consultants for assistance
in measuring noise levels.
Safety information is provided to assist you in
developing or modifying your shop safety program.
You may wish to consult your insurance company,
local, state and federal regulations, and equipment
supplier to be sure your safety practices comply
with all relevant safety and environmental regulations.
Safe Practices for Ventilation and Dust Control
Fine particles that may be generated during fabrication operations for CORIAN® are classified
according to OSHA standards as Particulates Not
Otherwise Regulated. Use local ventilation and
dust collection to minimize dust concentrations in
the work areas. Workers sensitive to dust should
wear NIOSH-MSHA–approved dust masks.
Material Safety Data Sheets for CORIAN® and
CORIAN® adhesives outlining health and safety
information are available through your Authorized
Distributor of CORIAN®.
Safe Practices for Lifting and Handling CORIAN ®
• To lift pallets of CORIAN®, use either a forklift
or hand-operated lift of appropriate capacity.
• To load and unload pallets of CORIAN®, use a
lift with fork extenders to prevent dragging or
damaging the material.
• When handling CORIAN® manually, workers
should:
—Wear heavy-duty work gloves and
safety shoes.
—Grasp sheets of CORIAN® by the edges,
not by the smooth surface areas or the
nylon straps.
—Carry single sheets vertically to
prevent flexing.
Explosion
Dust from CORIAN® does not present a danger of
explosion. Independent laboratory tests at Factory
Mutual Research and by DuPont’s Engineering
Test Center confirm that even when dust from
CORIAN® is finely divided and mixed with air,
chances of an explosion occurring are remote.
Flammability
Deposits of dust from CORIAN® will burn when
exposed to a flame or other ignition source.
However, the fire will not spread and goes out
when the ignition source is removed.
Fumes
Frictional heat generated from sawing and routing
CORIAN® can reach or exceed temperatures of
570°F (300°C). This is high enough to release
small amounts of methyl methacrylate vapors that
can be smelled in concentrations as low as one
part per million. Vapors can also be present at the
cutting tool face that exceed the threshold limit
value (TLV) of 100 ppm. They dissipate with
good ventilation, however, to very low levels
only a foot or two from the tool. For this reason,
localized ventilation should be provided where
extensive cutting operations are done.
Safe Practices for Working with CORIAN ®
• When working with CORIAN ®, workers should:
—Wear safety shoes, safety glasses with
side shields, goggles or face shields for
eye protection.
—Use ear protection if noise levels from
sawing, routing or other machining operations exceed federal or local safety levels.
—Wear a dust mask when fabricating CORIAN®
if ventilation is inadequate to keep dust
levels below acceptable limits. Refer to
Technical Bulletin, CTDC-111, CORIAN ®
Safety Information for Dust and Fumes,
E-97371, for details.
—Provide adequate ventilation when using
all adhesives and denatured alcohol.
People with unusually high sensitivity may
experience eye, nose or throat irritation from
dust and fumes from CORIAN® and should take
proper precautions.
Always follow the manufacturer’s safety
precautions when using panel adhesive, alcohol
and silicone.
Because state and federal regulations vary, DuPont
recommends that you consult local, state or federal
health and safety agencies, insurance companies,
5
Designing with CORIAN®
CORIAN® offers unlimited design possibilities in residential and commercial applications. You can select from a
full line of sinks and lavatories, including single-bowl,
double-bowl and double-bowl with molded drainboard
designs. To create a look of your own, single-bowl sinks
and lavatories can be combined to give you unique
double- and even triple-bowl designs.
And, nothing completes a sink or lavatory of CORIAN® like
a CORIAN® countertop. You can select from a variety of
colors and textures, plus many inlay colors and materials,
to make a work surface that’s as pleasing to look at as it is
to use. For the finishing touch, team up your imagination
with CORIAN® to create a unique design statement, such as
a custom-crafted drainboard, a monogrammed soap dish
or a thermoformed pedestal stand.
6
7
General Guidelines
Checking for Color Match
Designing Multi-Bowl Installations
Before installing bowls and sheets of CORIAN®,
check for color match. The best method for doing
this is to place the sheets and bowls next to each
other and examine them under lighting similar to
that found at the final installation site.
Sinks and lavatories of CORIAN® can be installed
in an almost infinite variety of combinations.
Self-rimming bowls can be placed as close
together as possible. This leaves a clean, sanitary
seam area.
Adding a shadow line to the bowl area can disguise
a shade difference. For example, recess mounting
a bevel (“A”) mount bowl or routing the inside
edge of a seamed (“S”) undermount bowl can hide
slight color differences. Inlays can help, too. Using
different color bowls and sheets is another design
alternative.
To create an integral top-and-bowl look with two
or more “S” bowls, trim the flanges to about 1⁄2″
(12 mm) before mounting. This design is especially attractive in kitchen installations. To avoid
“crack starters,” fill the gap between the bowls
with Joint Adhesive.
Bevel (“A”) mount bowls require some space
between them. A minimum of 1″ (25 mm) of
countertop is necessary between the flange
edges, and support should be added. A 2 × 3
support on edge will fit between the bowls, even
when bowls are placed at the minimum distance.
Locating Cutouts
Locate cutouts in accordance with the design
specifications and the following guidelines. Keep
cutouts for sinks and lavatories away from cooktops, stoves and other electrical appliances. The
possibility of water spilling into the appliance
could present a safety hazard. You can locate
seams in sink cutouts, as long as the seam is
fully reinforced along its entire length.
Special design features, such as drainboards and
soap dishes, can be added to customize a counter
or vanity top and give it that “signature” touch.
These can be easily routed to give the consumer
a truly unique installation.
Supporting Cutouts
Support sink cutouts like cooktop cutouts. Locate
strips between 1″ and 3″ (25 mm and 76 mm) from
the edge of the cutout. Use a support material that
will provide minimum flex, such as structural
lumber or minimum five-ply plywood.
Locating Faucets
Locate faucets in accordance with the design
specifications for the installation. Unusual faucet
placements can add a touch of distinction. For an
interesting look, spread out the controls or offset
the spout to one side.
8
Templates, Tooling and Accessories
Using Templates
Table II. Tooling for Installing
Sinks and Lavatories of CORIAN ®
When making cutouts, a template should be used.
For undermount, self-rimming and seamed undermount sinks and lavatories, consult Technical
Bulletin, CTDC-104, Making a Template from a
Paper Pattern, E92464, for detailed instructions on
making a hard template from a paper pattern. For
bevel (“A”) mount sinks and lavatories of CORIAN®,
Table I lists ordering numbers for hard templates.
Because the bevel must be exact, do not attempt to
make these templates. They are available from your
Authorized Distributor of CORIAN® and should be
used with a 30 mm template guide.
Self“A”
Rimming Mount
3 HP router
13⁄4 HP router
3
⁄8 ″ (10 mm) single-flute,
carbide-tipped router bit
Belt sander
Orbital sander
1″ (25 mm) template
“S”
Drain- Traditional
Mount board
Undermount
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
1
⁄2″ (12 mm) double-flute,
carbide-tipped router bit
Table I. Hard Templates for Bevel (“A”) Mount
Sinks and Lavatories of CORIAN ®
•
•
•
•
30 mm template guide
Sink/Lavatory
Model Number
Template
Catalog Number
802A/S
C991-00802
804A/S
C990-00019
805A/S
C990-00020
809A/S
C991-00809
810A/S
C990-00028
815A/S
C991-00815
816A/S
C991-00816
820A/S
C991-00820
830A/S
C990-00012
831A/S
C990-00027
850A/S
C991-00850
Paper or hard template*
854RA/LA
C990-00011
DuPont Joint Adhesive
857A/S
C990-00021
Various grits of sandpaper
859A/S
C990-00023
Scotch-Brite pads
871A/S
C991-00871
872A/S
C991-00872
874A/S
C990-00026
892A
C990-00031
Profiler bit
15° bevel bit
Bevel bit with
tapered nylon bearing
•
Decorative bit
•
•
•
•
Core box bit with altered tip
Mortising bit
Table III. Accessories for Installing
Sinks and Lavatories of CORIAN ®
Self“A”
Rimming Mount
Assorted clamps
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Denatured alcohol and
clean, white rags
•
•
•
•
•
Color-matched
Silicone Sealant
•
®
Selecting Tooling and Accessories
Aluminum tape
Tables II and III list the tooling and accessories,
respectively, needed for each type of installation.
Refer to the CORIAN® Fabrication Manual,
C956-H71343, for complete ordering information,
including sources.
Undermount hardware
•
“S”
Drain- Traditional
Mount board
Undermount
•
•
•
•
•
*For bevel mounts, order the hard templates listed in Table I on this page.
Scotch-Brite is a registered trademark of the 3M Company.
9
Installing Self-Rimming Sinks and Lavatories
1. Position and secure the template for the
cutout.
5. Apply Silicone Sealant.
• Clean the countertop around the cutout area
with denatured alcohol and a clean, white cloth.
• Rest the bowl upside down on a clean, smooth
surface. Clean the underside flange area with
denatured alcohol and a clean, white cloth
(see Figure 4).
• Apply a generous, continuous bead of
color-matched Silicone Sealant to the underside flange area, making sure the adhesive
extends to the outer edge (see Figure 4).
2. Rout the cutout.
• Make the cutout using a 2 HP to 3 HP router
with a 1″ (25 mm) template guide and a 3⁄8 ″
(10 mm) carbide-tipped, single-flute bit
(see Figure 1).
Figure 1
• Remove the template.
• Use an orbital sander to ease the edges of the
cutout (see Figure 2).
Figure 4
6. Position and secure the bowl.
• Turn the bowl over.
• Position the bowl on the sheet (see Figure 5).
Figure 2
Countertop
3. Trial-fit by positioning the bowl on the sheet.
• Position the bowl on the sheet, checking for a
Figure 5
7. Remove the excess sealant with denatured
alcohol and a clean, white cloth.
8. Seal between the bowl and the sheet.
• Use Silicone Sealant to caulk between the
bowl and the sheet. Smooth the bead.
• Clean the excess caulk with denatured alcohol
and a clean, white cloth.
tight fit (see Figure 3).
Figure 3
• Modify and re-sand the cutout, if needed.
4. Use a hole saw to make the faucet holes.
9. Let the sealant cure overnight.
10
Fabricating and Installing Bevel Mount (“A”) Sinks and Lavatories
NOTE
5. Trial-fit the bowl.
• Position the bowl approximately 1⁄32″ to 1⁄16″
(1 mm to 2 mm) above the sheet surface
(see Figure 7).
• Make additional trim cuts as necessary,
lowering the bit 1⁄16″ (2 mm) each time.
• Remove the template.
This procedure requires two installers to
properly apply the adhesive.
Flush-Mounting Sinks or Lavatories
1. Make sure the countertop is completely level
to ensure proper sink fit.
2. Position and secure the template for the cutout. (Some “A” mount sinks are narrower than
standard sinks. You may wish to ask your customers how they would like the sink positioned
in the sheet.)
3. Rout the cutout. Use a 3⁄8″ (10 mm) single-flute
bit and a 30 mm template guide.
4. Bevel the cutout edge with a 15° bevel bit
(see Figure 6).
• Install the 15° bevel bit in the router.
• Set the router on the template.
• Lower the bit until it touches the sheet.
• Set the depth gauge to zero.
• Adjust the bit down to a depth of 1⁄2 ″ (12 mm).
• Rout around the inside of the cutout.
Figure 7
6. Apply Joint Adhesive, using two people and
two kits.
• Form a tape dam underneath the cutout. Do not
extend the tape more than 1⁄2″ (13 mm) into the
opening (see Figure 8).
• Clean the edges of the bowl and sheet with
denatured alcohol and a clean, white cloth.
• Turn the bowl over.
• Apply a thick layer of adhesive to the bowl and
to the edge of the cutout (see Figure 8).
Template
15° Bevel Bit
CORIAN®
Figure 6
Figure 8
continued
11
Fabricating and Installing Bevel Mount (“A”) Sinks and Lavatories (continued)
Recess-Mounting Sinks or Lavatories
7. Set the bowl in the cutout, aligning it with the
sheet surface.
1. Follow flush-mounting steps 1 through 7
exactly.
• Make sure that the bowl edge is the same
height on all sides (see Figure 9).
• Make sure that the tape underneath the sheet
has not peeled away.
NOTE
To ensure exact repositioning of template, mark
its position with two hot-melt glue blocks on the
underside of the template and one block on the
sheet of CORIAN® (see Figure 7).
Align
Edge of
Bowl
2. Follow step 8 under Flush-Mounting; except,
before using the belt sander, use a profiler bit
and a 30 mm template guide to recess the
edge of the bowl (see Figure 11).
• Replace template.
• Install the profiler bit in the router.
• Set the bit on the lowest point of the bowl lip
or 1⁄8 ″ (3 mm), whichever is lower.
• Rout the lip of the bowl. Check the rout for
smoothness and to ensure enough material is
removed. If necessary, lower the bit slightly
and rerout.
Countertop
Figure 9
8. Allow the adhesive to cure for 45 minutes.
9. Using a belt sander, level the edge of the bowl
with the sheet (see Figure 10).
• Remove scratch marks with an orbital sander.
• Finish sanding with a Scotch-Brite® pad.
NOTE
The flange on some “A” mount bowls is extrawide and will require additional trimming.
Rerout by using either the profiler bit slightly
away from the template or by removing the
template and making a pass with a 1⁄4″ (6 mm)
or 3⁄8 ″ (10 mm) radius roundover bit. (This bit
reduces sanding time.)
• Remove the template.
Figure 10
Figure 11
3. Continue with step 8 under Flush-Mounting.
12
Fabricating and Installing Traditional Undermount Sinks and Lavatories
NOTE
The procedures for installing undermount
kitchen (below) and bar/vanity (page 15) sinks
and lavatories differ. Refer to the procedure
that corresponds to the type of undermount
sink or lavatory you are installing.
Fabricating and Installing
Undermount Kitchen Sinks
Figure 13
1. Prepare the bowl.
• Check to see if the faucet assembly can clear
the combined thickness (11⁄4 ″ to 11⁄2 ″ [32 mm
to 38 mm]) of the CORIAN® countertop and
sink (see Figure 12). It may be necessary to
change faucet sets.
3. Install the sink in the frame.
• Place a 1″ (25 mm) spot of Silicone Sealant at
each corner of the frame where it will contact
the sink.
• Gently position the sink within the frame
(see Figure 14).
• Check the sink flange for levelness and for
proper mating height with the perimeter
support at the cutout area. Adjust or shim,
if needed.
Sink
Faucet Deck
Combined
Thickness
Countertop
Silicone Sealant
Figure 12
2. Prepare the support frame for kitchen sinks.
• Measure the size of the kitchen cabinet opening where the sink will be installed.
• Construct a plywood frame, allowing adequate clearance between the strips running
front to back. These will support the sink
(see Figure 13). See recommended clearances
on the templates.
• Position the frame within the cabinet opening
so that when the sink is installed, the top of the
sink flange is level and flush with the top surface of the perimeter support at the cutout area.
• Firmly attach the frame to the cabinet interior
with screws (see Figure 13).
Figure 14
4. Prepare the sheet.
• Cut the sheet for the countertop to the proper
length and width.
• Trial-fit and adjust, if needed.
5. Position and secure the template for
the cutout.
• Carefully measure the countertop to determine
the exact location of the cutout.
• Clamp the template in position.
continued
13
Fabricating and Installing Traditional Undermount Sinks and Lavatories (continued)
6. Rout the cutout.
• Make the cutout using a 2 HP to 3 HP router
with a 1″ (25 mm) template guide and a 3⁄8″
(10 mm) carbide-tipped, single-flute router
bit (see Figure 15).
• Rout the faucet holes. (Faucet holes can
be made using a hard template and router
or a high-speed electric drill with either a
spade bit, twist drill or hole saw. Do not
use auger bits.)
• To minimize sanding, smooth the inside
of the cutout with a 1⁄2″ (12 mm) doubleflute, carbide-tipped bit and a 1″ (25 mm)
template guide.
• Remove the template.
• Use an orbital sander to smooth the cutout
area and to remove all router marks.
• Rout decorative design into edge of cutout
if desired.
Figure 16
Fabricating and Installing Undermount Bar/Vanity
Sinks and Lavatories
1. Turn sheet upside down and position and
secure the template for the cutout.
Single-Flute
Carbide-Tipped Bit
2. Rout the cutout.
• Use a 2 HP to 3 HP router with a 1″ (25 mm)
template guide and a 3⁄8″ (10 mm) carbidetipped, single-flute bit (see Figure 17).
Double-Flute
Carbide-Tipped Bit
Figure 15
7. Install the countertop over the sink.
• Clean the top of the sink flange with denatured
alcohol and a clean, white cloth (see Figure 16).
• Clean the bottom of the countertop around the
cutout area with denatured alcohol and a clean,
white cloth.
• Apply a generous bead of color-matched
Silicone Sealant around the top inside edge of
the flange (where sink wall and flange meet).
• Position the countertop over the sink, being
careful that the Silicone Sealant provides a
complete seal where the surfaces mate.
• Remove the excess sealant; then wipe the
joint with denatured alcohol and a clean,
white cloth.
Figure 17
• Remove the template.
• Use an orbital sander to smooth the cutout if
needed (see Figure 18).
14
Bolt
Wing Nut
Washer
Bracket
Brass Insert
Figure 18
3. Trial-fit the bowl.
• Position the bowl over the cutout, checking
for a tight fit (see Figure 19).
• Modify and re-sand the sheet, if needed.
Figure 20
6. Fasten the bowl to the top.
• Clean the bowl’s top flange and the cutout
with denatured alcohol and a clean, white
cloth (see Figure 21).
• Assemble the undermount hardware
(see Figure 20).
• Screw the bolt assemblies into the brass
inserts.
• Apply a generous bead of color-matched
Silicone Sealant to the inside edge of the
bowl flange (see Figure 21).
• Install the bowl over the cutout.
• Tighten the wing nuts to secure the bowl.
• Make sure that the joint is completely filled,
then remove the excess sealant with denatured
alcohol and a clean, white cloth.
Figure 19
4. Make the faucet holes.
• Use a template and a router or a high-speed
electric drill equipped with either a spade bit,
twist drill or hole saw.
• Do not use auger bits.
5. Install brass inserts.
• Center the bowl face down over the cutout.
• Locate the holes 1″ (25 mm) from the side
edges of the bowl flange and away from the
bowl’s front and back edges to allow clips
to clear the cabinet frame (see Figure 20).
• Drill 1⁄4 ″ wide by 1⁄4″ deep (6 mm by 6 mm)
holes into the sheet.
• Remove the bowl and drive the brass inserts
into the holes in the countertop, slotted end
in first.
Figure 21
continued
15
Fabricating and Installing Traditional Undermount Sinks and Lavatories (continued)
7. Install the countertop and sink on the cabinet.
• Place a 1″ (25 mm) spot of flexible adhesive,
such as Silicone Sealant for DuPont CORIAN®,
every 12″ (305 mm) around the top cabinet
support (see Figure 22).
Figure 22
• Position the bowl and countertop unit
on the support.
16
Fabricating and Installing Seamed Undermount (“S”) Sinks and Lavatories
Constructing a Bowl Cutout Template
A multifunctional bowl cutout template (see
Figure 23) can be designed to accommodate:
• Bowl cutout. The template opening should
be the same size and shape as the inside
circumference of the bowl. Use a 1″ (25 mm)
template guide and a 3/8″ (10 mm) bit to leave
a 1/4″ (6 mm) overhang. The overhang will be
trimmed after seaming.
• Faucet holes.
Figure 24
2. Prepare the sheet.
• Check the back of the sheet for smoothness,
and belt-sand, if needed (see Figure 25).
• Remove the scratch marks with an orbital
sander.
Faucet Holes
Figure 23
Figure 25
Fabricating and Installing Seamed Undermounts
3. Rout the cutout.
• Clamp the bowl cutout template in position
(see Figure 26).
• Make the cutout using a 2 HP to 3 HP router
with a 1″ (25 mm) template guide and a 3⁄8″
(10 mm) carbide-tipped, single-flute bit.
• Rout the faucet holes. (See “Constructing
a Bowl Cutout Template” for template
construction.)
1. Check bowl flange for flatness.
• Rub an aluminum level over the flange of
the sink.
• Hand-sand to level high spots (see Figure 24).
CAUTION
Be very careful when hand-sanding the bowl
flange. Improper sanding may round the edge,
resulting in a poor seam. As an alternative,
turn the bowl upside-down and rub it on a flat
surface, such as a bench or an old door, covered
with sandpaper.
continued
17
Fabricating and Installing Seamed Undermount (“S”) Sinks and Lavatories (continued)
NOTE
To avoid trapping air in the seam when the
bowl is set in place, make only one continuous
bead around the bowl. Use only radial lines of
adhesive on remainder of flange.
Figure 26
4. Trial-fit by positioning the bowl on the sheet.
• Position the bowl on the sheet, checking for a
tight fit; sand sheet, if needed.
• Use hot melt glue to adhere position blocks to
the sheet (see Figure 27).
Figure 28
6. Position and secure the bowl.
• Position the bowl on the sheet between the
stop blocks (see Figure 29).
Figure 27
5. Apply Joint Adhesive.
• Carefully inspect the inside bowl edge. For
a good seam, it must be square, smooth and
scratch-free.
• Clean the flange surface and the sheet around
the cutout with denatured alcohol and a clean,
white cloth (see Figure 28).
• Apply a generous, continuous bead of Joint
Adhesive to the bowl flange 1⁄4″ to 3⁄8″ (6 mm
to 9 mm) from the inside edge of the bowl (see
Figure 28).
• Apply radial lines of adhesive on the rest of
the flange.
Figure 29
• Secure the bowl firmly in place.
• Inspect the seam area inside the bowl. Make
sure adhesive is around the entire perimeter of
the mounted bowl and sheet.
WARNING
Use caution when inspecting the inside of the
bowl. Joint Adhesive vapors will be present in
the bowl.
18
H
HELPFUL HINT
HELPFUL HINT
For clamping bowl to sheet until adhesive sets:
Some bits rout the sheet back to the bowl and
make a roundover in one step. This saves time
by combining steps 7 and 8.
• Clamp the bowl to the sheet by placing a pipe
clamp through the drain hole (see Figure 30) or
use a bowl clamping jig. Heavy weight, such
as 50-lb. bags of salt, can also be used.
• Sand the inside seam with 120-grit sandpaper
or 100-micron microfinishing film abrasive
using a random orbital sander (see Figure 32).
• Finish-sand using 150-grit sandpaper or 60micron microfinishing film (see Figure 32).
Masking Tape
Figure 30
• Allow the Joint Adhesive to cure for 45
minutes (see Figure 31).
• After curing, turn the unit over carefully.
Figure 32
8. Rout a decorative edge.
• Place masking tape around the bowl where the
roller bearing of the router bit rides. This helps
prevent scoring of the bowl and reduces the
sanding needed for final finishing.
• Rout a decorative edge on the sheet, such as
a chamfer, ogee or roundover.
9. Finish-sand.
• Finish-sand the edge and seam area with
an orbital sander and 180- to 220-grit paper.
This step is not needed if microfinishing films
are used.
• Buff the entire top and bowl area with a
Scotch-Brite® pad to produce a uniform,
matte finish.
Figure 31
7. Prepare for finishing.
• Rout the sheet back to the bowl using a
carbide-tipped bevel bit with a nylon bearing
to reduce scoring (see Figure 32). This trim cut
approximates the bowl angle.
19
Routing Drainboards into CORIAN® Countertops
The following information can help you turn
your drainboard designs into reality. The only
restrictions on your imagination are:
• The maximum rout depth that can be used is
3
⁄16″ (5 mm) and
• Routed drainboards cannot be used with
self-rimming bowls.
Perimeter
Template
Groove
Template
Selecting a Design
Figure 33 illustrates just a few of the many drainboard designs that you can fabricate. Many times,
the type of bowl selected dictates the outline of the
drainboard; for example, whether the sides are
straight or curve into the bowl.
Figure 34
You can select from three types of interior routing
designs—ridged, grooved or recessed—all of
which are described in this guide.
2. Make the template.
• To resist flexing, use 3⁄4″ (19 mm) plywood or
MDF to make the template (see Figure 35).
Reinforce the sides with metal angle brackets,
if desired.
NOTE
Make the template wide enough to allow the
router to pass the clamps.
• Label the template with router bit, template
guide and bowl model information so you can
use it again.
Perimeter
Template
Figure 33
Groove
Template
Making Templates
1. Make a full-scale drawing of the drainboard
design on paper (see Figure 34).
Figure 35
20
Fabricating Drainboards
• Cut on the template guide lines. If needed, add
reinforcements inside. Make allowances for
reinforcing pieces.
• Add a strip underneath the open end to prevent
spreading.
For bevel or submounted bowls, install the bowl
before routing the drainboard.
1. Lay out the drainboard on the sheet of
CORIAN® and carefully position the template.
• Rest the template end near the bowl on the
sheet (see Figure 36).
• Clamp securely, being careful not to flex the
sides of the template (see Figure 36).
2. Mark the position and secure the template.
3. Adjust the bit height.
4. Rout the design (see Figure 37).
2. Rout the perimeter.
• Rout the perimeter design into the top using a
core box bit with an altered tip (see Figure 36).
Core Box Bit
Core Box Bit
Figure 37
For Ridged Designs
1. Follow the same steps for making a grooved
design; however, you must make the grooves
much wider.
Figure 36
Routing the Interior:
For Grooved Designs
To do this:
• Make the areas for the template guide wider, or
• Move the template to rout wider grooves.
1. Make the template.
• Lay out the design on the template material.
• Mark the center line of grooves.
• Enlarge the groove design to accommodate
the template guide.
continued
21
Routing Drainboards into CORIAN® Countertops (continued)
For Recessed Designs
Finishing
1. Leave the perimeter rout template in place
(see Figure 38).
1. Hand-sand grooves to remove router marks.
• Use 150-grit sandpaper, followed by finer grits,
until all the scratches are removed.
2. Use a hinge mortising bit in a router with an
extended base plate (see Figure 38).
2. Round the upper edges of the grooves to
approximately a 1⁄8 ″ (3 mm) radius.
Mortising Bit
Figure 39
3. Use a random orbital sander and a
Scotch-Brite® pad to finish-sand (see
Figure 39).
Figure 38
3. Make a grooving pass.
• Make one right-to-left cut on the bowl edge
of the sheet to prevent chipping along the edge
while routing.
NOTE
For recessed designs, use a belt sander gently to
remove the router bit marks if needed. Then,
finish-sand and buff with a Scotch-Brite® pad to
a uniform matte finish.
4. Complete the interior rout.
CAUTION
Do not apply downward pressure while routing.
This causes an uneven rout, necessitating extra
sanding.
22
For additional information or assistance, contact
DuPont CORIAN®
Wilmington, Delaware 19805
1-800-4-CORIAN® (1-800-426-7426).
C956-H71347 4/97
Printed in U.S.A.
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