Installing Corian Countertops

Base Cabinets

Successful installation of solid surface countertops begins with solid cabinetry. Remove the old countertops and inspect the base cabinets. The cabinets need to be sturdy and flat across the top. If the cabinets are not flat, use shims so that they become both flat and level. Because solid surface countertops are so heavy, add support cleats to the top of the cabinets. Also add support cleats above the opening for a dishwasher and in the case of undermounted sinks, across the tops of the cabinet where the sink will be. If the counter will have a peninsular that sticks out beyond the cabinetry then install three quarter inch plywood to support the Corian countertop.

Cutting and Fitting

Fit the sheet of Corian and cut to length before installing. The first sheet of countertop to be installed must have a seam support strip at one end of the counter. Then lay the sheet on the cabinetry, fitted against the wall. If necessary, scribe and contour the back edge of the countertop using a power belt sander so that it fits flush against the back wall, this is important if the walls are not straight. Mark a cutting line using masking tape, in case the countertop needs trimming. Next, make the cutout for the sink. Whether using an undermount sink or purchasing a regular sink, use the provided template to align and clamp in place while using a router to cut out the opening for the sink.

Joining Edges and Finishing Countertop

Once the kitchen countertops are cut and fitted in place, join the seams together using epoxy. Join the cabinet to the cabinetry with silicone. When joining two pieces of countertop together, first clean with denatured alcohol so that they are free of debris, and then join together using a tinted epoxy. Once the epoxy has dried, sand the seams down with a power sander so that the Corian countertop has the appearance of being seamless. Then bond the countertop to the cabinets using silicone. To give the countertop a high gloss finish, buff the counter tops using a polishing bonnet attachment. Then install the backsplash. Finally install the sink, connect the oven and the countertop is finished.