Making a router table top, plastic laminate/kitchen worktop

[Dissolve]

Hello,

I'm about to start making my router table and I want a decent top, I haven't had much luck finding a kitchen worktop offcut so I'm considering making my own out of laminated MDF.

Does anyone have tips for laminating your own top? Such what's better, laminating more pieces of thinner mdf or two thick 18mm boards?

I want a durable plastic laminate on top of the MDF similar to commercial router tables. Can anyone suggest a source for suitable plastic laminate?

Thanks

 

[Random Orbital Bob]

Hi Cheerup

Have a read through this thread:

plastic-laminate-and-where-to-get-it-t70478.html

It has some useful responses on where to get sheets of laminate from.

On the issue of mdf. The issue is of course rigidity. If there is any sag in the top over time then clearly that's going to affect the work.

The general consensus seems to be gluing together two sheets of 3/4" mdf and then laminating that. I would also edge band it with a hardwood personally. Also on a personal note, I wouldn't use mdf, I would use a decent quality ply (like marine ply). Ply is substantially more rigid than mdf for exactly the reason you discuss namely..its been laminated. Its also laminated with grain at right angles to each successive layer which gives it tremendous strength. The more expensive ply's are made up of superior hardwoods AND more layers of thinner plys (like marine ply). That would be my material of choice but the downside is it is expensive.

I have an mdf laminated router table and the top does in fact sag. I have to shim the router from underneath to prevent it's weight causing the top to sag in the middle. It was made commercially and the mdf is inch.

So to summarise: 2 pieces of 3/4" mdf with edge-banded hardwood and then laminated will probably do if the top isn't too big. Relatively cheap. Another risk is the resultant cutter hole will be circa 36mm in depth which means you may find that for some operations you need a collet extension to get the cutter high enough for the work. I reckon about an inch thickness of good quality ply...then laminated is the perfect solution.