Modular Counter Top Manual - Page 4

STEP 8:
After the seam has cured, carefully use a belt sander with (80) grit sandpaper to knock down the glue and level the seam area. Be careful not to get the seam hot. Finish rough sanding with (80) grit sandpaper on an 8" circular or orbital sander. Inspect seam area for flaws and flatness.

STEP 9:
Recheck template (or measurements) and remark as needed. Include any sink centers or other cut out locations.

ROUTING AND SANDING

STEP 1:
Begin by straight edging, any and all, out-of-square ends or areas that or not true to template shape. Remember to trim off at least 1/16" to 1/8" from all finished edges. All modular finished edges have a waxy, milky layer on them due to the molding process by which they are made, and must be removed for a quality looking finished product. (A simple method to removing this layer is 'in next step)

STEP 2:
Because 99% of all layout starts at the front edge to the back, the front edge 'is normally the longest finished edge, and the most true to template / measurement. Therefore, these edges are ideal for a 1/2" height 1/8" deep inlay bit Using this bit in a router, cut a groove along the middle of the front edge and any other finished edges that are true to template / measurement that did not need to be adjusted previously.

STEP 3:
Now, use a flush trim (bottom bearing) bit to remove the top portion of the edge. To remove the remain~g bottom portion of the edge, you can use a top mount bearing flush trim bit if desired. If not, simply turn counter top over and flush trim from the bottom side of the modular.

STEP 4:
After flush trimming, turn counter top over if not already done. Looking at the bottom side of the modular, you will notice long 80 grit belt sander scratches on all finished edges and along the back rail. These areas should be lightly sanded to feel good, not to look good, with a 60 micron or 220 grit sandpaper (because they will not be seen, only felt, by the customer). Seam areas will require more aggressive sanding procedures, like using 80 grit paper first, then use the finishing grit.

STEP 5:
It is "ok" for the customer to feel the bottom of the edge, but it is not "ok" for the customer to feel or see the bottom of the counter top itself! So, if there are any areas that overhang the cabinet and expose the underside of the counter top, these areas need to be filled with melamine or plywood. This will give added support, especially for large overhang situations. Apply at this time.