A building material made out of aluminum and acrylic is called Corian.It is mistaken for marble or granite when used for countertops.It is easy to cut Corian, but it is important to wear protective eyewear and wear a dust mask.Dust from cutting Corian can irritate the lungs and eyes, so it's a good idea to work in aventilated area.
Step 1: Take a look at the area where you're installing your Corian.
Measure your area using a retractable measuring tape.Make sure to double-check your measurements.You can refer to the dimensions on a piece of paper by Jotting them down.If your initial measurement was off, you don't want to waste an entire slab of material.
Step 2: Place your work surface upside-down.
Two sawhorses, a stable workbench, and a cutting table can be used to cut Corian.If you have a large slab of Corian, you should use a larger workbench.If necessary, use a clamps to hold the Corian in place.
Step 3: You should mark where you are going to cut with a grease marker.
To mark the dimensions that you need to cut with a grease marker, use your previous measurements on the underside of your Corian.If you want to steady your hand as you draw your lines, use a straight edge and tilt your marker at a 45 degree angle.There are no visible markings left on the underside of the Corian after you have installed it.
Step 4: Attach a triple chip blade to your saw.
You can use a circular saw to cut Corian, but the blade has to be a triple chip blade.Any other saw blade can damage your saw.Losing control of your circular saw could be disastrous.The material and blade type will be printed on the side of the saw blade.
Step 5: Put on a dust mask or a protective eyewear.
There are health risks associated with cutting the chemical components of Corian.Dust caused by cutting can damage your lungs, throat, and eyes.Before you start cutting, wear protective eyewear and a dust mask.You should make your cuts in aventilated area.
Step 6: Clean cuts can be made by placing a straight edge next to the guiding line.
Attach a leveler 1.5 inches away from your grease marking, parallel to the guiding line that you are going to cut.The guiding line on the saw should be on top of one another if you place the base plate against the straight edge.If you need to move the straight edge, make adjustments to the placement of your leveler.A straight edge will support the base plate of your circular saw while you cut.You can tell if you have a level surface if the air bubbles float in the middle.The leveler should be on the opposite side of the saw.If you put too much pressure on the straight edge, your blade will slide away as you cut.
Step 7: Put the saw on top of the grease marking.
On the edge of your slab of Corian, use the guiding line on the base plate of the saw to line it up with the grease marking where you want to cut.Lift the lever on the side to set the depth of your blade.The bottom of your Corian slab should allow your blade to extend slightly beyond it.Before you start cutting, make sure you put your hands on the upper handles of the circular saw.
Step 8: Cut along your line by pulling the trigger on your saw.
You should wait for the blade to spin before moving it.As your blade begins to cut the Corian, stop pushing.The saw will do the work for you, and the blades will pull it forward.Wait for your blade to stop before moving it.
Step 9: If you see kickback or smoke, release the Trigger.
A lot of heat can be created by the friction between the saw blade and the Corian.If you move too quickly, your saw blade will start to smoke.Wait for a few minutes and let your blade cool down.Wait for a moment before you resume cutting if your blade jumps as you cut and kicks back.
Step 10: If you missed a piece, inspect your edges.
If you missed any chunks of Corian with your circular saw, look along every edge where you cut.If you missed a section, you can cut it again with your circular saw, but you need the edges of your Corian to be flat.
Step 11: Start by using 100-150 grit sandpaper.
To begin smoothing your edges, use medium-grit sandpaper.Turn on your sander by attaching your sandpaper to it.Carefully press it into the material so that it rests on top.To remove excess bumps and sharp edges, slide your sander back and forth along the edges.You can use a belt or disc.Both of them will work for the job.You can sand your edges by hand, but it will take a bit of energy and won't result in a uniform finish.
Step 12: If you are having trouble getting a clean finish, move up to a higher grit.
The sides and edges of your Corian can still be rough after a few applications of the sandpaper.The smaller bumps and groves in your Corian will be worn away by the lighter sandpaper.
Step 13: To inspect your edges, run your hand along them slowly.
Run your hand along the edge of your Corian.If the sides are smooth to the touch, you are done sanding and ready for installation.Continue sanding if they are still bumpy or coarse.