- 1). Measure the countertop front to back and side to side, using a tape measure. Mark the dimensions on a piece of cardboard, using a pencil. Cut it out with a utility knife. Test fit the cardboard template. Recut as needed to get a perfect fit.
- 2). Place the cardboard template on the back of the plastic laminate. Outline the template with a marker. Cut the laminate to size ½ inch larger than the template on all sides. Use a table saw with a fine-tooth blade turned backward to make the cuts with the least amount of chipping.
- 3). Apply a coat of contact cement to the countertop and the back of the laminate with a roller. Wait for it to dry, typically 10 to 15 minutes. Center the laminate over the countertop and set in place. Use a rolling pin or J roller to press the laminate down to get a good bond.
- 4). Cut the edges of the laminate with a router and flushcut bearing bit. Adjust the depth of the router by loosening the adjustment bolt. This is on the side of the router, bridging the split in the router's plastic base. Turn the wing nut counterclockwise to release it. Twist the router clockwise to lower the bit and counterclockwise to raise it. Adjust the height so that the blade of the bit cuts completely through the laminate and the bearing will ride on the edge of the countertop material.
- 5). Set the router on top of the laminate and start the motor. Allow it to come up to speed. Run the router clockwise around the countertop to cut the edges of the laminate flush with the edge of the countertop. Apply steady pressure and move the router smoothly around the edge to avoid chatter, or chipping.
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