Time

A full day

Complexity

Intermediate

Cost

Varies

Introduction

Step-by-step instructions on how to install a pre-made plastic laminate countertop in your kitchen or bathroom.

Tools Required

  • 4-in-1 screwdriver
  • Belt sander
  • Caulk gun
  • Circular saw
  • Clamps
  • Cordless drill
  • Drill bit set
  • Dust mask
  • File
  • Handsaw
  • Hearing protection
  • Jigsaw
  • Safety glasses
  • Scribing tool
  • Straightedge
  • Tape measure

Materials Required

  • 1-1/2 in. steel angles
  • 1-1/4-in. drywall screws
  • 5/8-in. long No. 8 screws
  • 80-grit sanding belts
  • Acrylic caulk
  • Masking tape
  • Miter bolts
  • Premade cabinets
  • Silicone caulk

Plastic laminate countertops have been adorning kitchen cabinets for more than 50 years—and with good reason. Plastic laminate is a tough, durable material that comes in hundreds of colors and finishes. When applied to particleboard or plywood underlayment by a production shop, this proven product is ideal for kitchens, bathrooms and other settings. By installing premade countertops yourself, you’ll save 50 percent of what a professional installer would charge. Want to add natural flair to your kitchen? Learn how to install butcher block countertops.

In this article, we’ll show you how to measure, buy and install your own countertops. Our instructions include how to make chip-free cuts, tight-to-the-wall scribes and nearly invisible joints for a professional-looking job.

The easiest approach is to order custom-made laminate countertops (ours cost about $30 per running foot) from a local home center, full-service lumberyard or cabinet/countertop shop. You can also buy premade take-it-with-you stock tops (in limited colors) at many home centers, for about half the price of custom countertops. Shop for the latest in plastic laminates on manufacturer Web sites.

You can also view product samples at home centers and countertop suppliers.

3 special tools make all the difference

  • A belt sander with an 80-grit belt is a must for removing material along the backside of the backsplash (Photo 7).
  • You also need a scribing tool (Photo 6) to make accurate marks along irregular walls.
  • A 10-in. mill file and a smaller half-round file will help you get perfect fits for end caps (Photo 12).
  • Besides these special tools, a 10-point or finer handsaw, drill, jigsaw, masking tape and tape measure are all you need.

When to call a pro

If you have a U-shaped kitchen with two large miters and have never installed countertops before, you may want to hire a pro. Configurations like this require you to scribe three walls at one time. But if you have only one inside corner as we did, the project is well within the skill level of the average do-it-yourselfer.

Measure first!

Make a sketch and then, starting from the back walls, measure the exact lengths from the walls to the edge of each run of cabinets. Add 3/4 in. to the length of each section to allow for overhangs. Allow an extra inch to protrude into a freestanding range space. You’ll trim it off later for an exact fit. Order a laminate end cap (or make your own.) If you need to butt the countertop into a side panel like a pantry or refrigerator cabinet, add an extra 1 in. for notching. This will give a more finished look than a straight cut. Also, measure the depth of your base cabinets. Standard laminate tops are 25 in. deep. Check to make sure you’ll have at least 1/2-in. overhang beyond all the drawer fronts.

Most manufacturers will supply preshaped and pre glued iron-on end caps to cover finished ends, but some prefer to order a little extra plastic laminate that they can score and cut and glue into place with contact cement for a longer-lasting grip. Either system works fine, but if this is your first go at this type of project, you’ll find the iron-on end caps easier to install. Just keep in mind you’ll need to do a bit of filing in either case to shape the end caps.

Another important consideration is corner and edge style. To fit our design requirements, we chose square corners for all our edges. If you want any rounded corners on exposed edges, discuss this with your supplier ahead of time and ask to see sample profiles.

You’ll also need build-up strips (usually 3/4 in.) to support the top across the cabinets. At first glance, countertops appear to be 1-1/2 in. thick, but the substrate that the laminate is glued to is actually just 3/4 in. thick, as the underside reveals. Applying additional build-up strips to the top of your cabinets will fill the void at support points and elevate the countertops above top drawers. When ordering, ask for build-up strips, but keep in mind you can easily make your own from scrap 3/4-in. plywood or 1×2 pine.

Once you complete your measurements, take your drawing to your countertop supplier and discuss your plan to make sure you’ve covered all the bases. If you don’t have a home center near you or your lumberyard doesn’t provide this service, check the internet for “countertops.” When you place your order, ask about delivery to your home. In most cases, the odd shapes are unwieldy and won’t rest securely on top of the family car.

Project step-by-step (20)

Step 1

Measure along the finished edge

Measure the hollow space under your new countertop for the correct build-up height before ordering your new ones. Your manufacturer can supply build-up strips, or you can cut them yourself. Our measurement was 3/4 in., so we used 1x2s as build-up strips.

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Step 2

Attach the build-up strips

Screw the build-up strips to the tops of your cabinets (sides and along the back) using 1-1/4 in. drywall screws. You may not need them on the cabinet end where the manufacturer has installed a finished end.

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Step 3

Test fit the counter corner pieces

You can start with any section of countertop, but it’s best to begin with the longest corner section because the other sections often join or relate to this piece. Our long section had a number of fitting challenges—especially the corner. To get an accurate scribe to the wall here, you need to temporarily join the corner, as pictured in the steps below.

Slide the counter corner pieces into position first to test fit for scribing. Since our corner cabinet had a solid top, we cut inspection holes to tighten the miter bolts.

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Step 4

Hold the counter corners together

Temporarily bolt the two corner pieces together from below. Use the special miter bolts that come with the countertop.

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Step 5

Tighten the miter bolts

Make sure the miter is flush on top as you tighten the bolts. Once the bolts are tight and the top is flush, slide the countertop into the corner and examine the fit along each wall.

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Step 6

Scribe the backsplash

This is the most crucial step.

Set your scribing tool to the width of the widest gap along each wall. Apply masking tape to the top of the backsplash and use your scribe to mark the entire length of each countertop. Scribe to each wall, adjusting your scribing tool each time for the largest gap on that wall.

Before you scribe, align the front edges of the countertop parallel to the cabinet fronts. Close gaps where the backsplash meets the wall if possible. Scribe the top as shown in Photo 6. Keep in mind you can remove up to 1/2 in. from the backside of the backsplash to fit your wall. This is more than enough in most cases, so don’t panic if your adjoining wall looks out of whack.

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Step 7

Sand to the scribe line

Belt sand to your scribe line using an 80-grit belt. Make sure the top is clamped down to your work surface to keep it from “walking” away from you as you sand. Sand only to your scribe line, keeping the belt sander at 90 degrees or more to the top of the backsplash as shown. Reposition the top and re-scribe and sand if necessary.

Next, remove the miter bolts and separate the sections so you can cut the sink opening.

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Step 8

Trace around the sink

Flip our sink upside down into position over the sink cabinet. If your sink is not symmetrical, use a template. Mark around the perimeter, then mark another line 1/2 in. inside the perimeter (1 in. for cast iron) you’ve just marked. This will be the cutout size.

Measure at least twice to locate the sink

You can get into trouble here if you don’t think through three important steps:

  • Center the sink over the sink base cabinet.
  • Set the sink back far enough to clear the cabinet front.
  • Cut the hole smaller than your sink’s rim.

For most stainless steel sinks, it’s safe to flip the sink over and trace around it and then make another line 1/2 in. inside the trace line (pictured below).

The exception here is an asymmetrical shape where the left side is different from the right side. Check this carefully, especially if you’re reinstalling your old sink and no longer have the original template (most new sinks come with a full-size template).

If you’re installing a cast iron enameled sink, you should make an even smaller cutout, leaving more countertop to support the weight of the sink. Usually most cast iron sinks will allow you to cut inside the traced perimeter at least 1 in.

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Step 9

Drill holes inside the template

Drill 1/2-in.dia. holes about 2 in. from each corner. The edges of the holes should just kiss the inside edge of the inner line.

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Step 10

Connect the drill holes

Flip the top upside down. Connect the dots. The lines should touch the outer circles of the 1/2-in. holes. Use a coffee mug to round the corners. Cut out the top from the bottom side with a jigsaw. Set the sink into the opening to check the fit.

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Step 11

Cut the opening from the bottom Side

Use a jigsaw with a medium-cut blade. The blade cuts on the upstroke, so do all your cuts from the bottom of the countertop to minimize chipping. Be sure the cutout is supported when you reach the end of your cut so you don’t break an edge. After the hole is cut, set the sink into the opening to check the fit. Do a bit of trimming if it binds as you drop it in.

Step 12

Use a handsaw to cut the countertop

Before assembling the miter joint, you’ll want to cut the short section of the countertop exactly flush with the cabinet end to make room for the range.

First, apply masking tape over the edge and then mark the cutoff line with a pencil. The masking tape serves a dual purpose here: It lets you easily see your pencil mark and it reduces chipping of the laminate as you cut.

Trim the end of the countertop with a sharp 10-tooth-per-inch handsaw. Cut 1/16 in. outside the mark. Then, belt-sand to the line.

Next, glue (use carpenter’s glue) and clamp a buildup strip onto the underside of the top and flush with the edge.

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Step 13

File the end cap

Once the glue is dry, you can apply matching plastic laminate over this built-up edge. If you don’t have a precut end cap, cut one from your extra piece of laminate. Make a couple of practice cuts with a laminate cutter (Photo 12) before you try the real thing. Set your laminate on scrap wood (not on your new countertop!) and draw the shape of the end cap plus 1/4 in. extra on both the top and front.

Score the top several times to cut through the laminate, using a straightedge as a guide. Be careful near the corner where the backsplash section leaves a right angle rise. It’s easy to break this little chunk off.

Apply contact cement to each mating surface and let it dry to the touch (about 20 minutes). Then, position the end cap even with the bottom edge of the build-up filler strip and press it firmly into place.

Using a dry rag, firmly wipe the surface to further press it for a good bond. Now file the end cap flush to the countertop (Photo 12). Take your time with slow, controlled strokes. When the edge is almost flush, slightly bevel the end cap to remove sharp corners that could snag a dishcloth later.

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Step 14

Caulk the miter joint

Squeeze a bead of siliconized acrylic adhesive caulk onto the edge of each miter joint and then fasten the countertop sections together as before. Be sure the tops are flush as you tighten the bolts.

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Step 15

Cutting a return

You may not have to make a “return” cut in your countertop like the one shown in the next three steps. If you do, follow this sequence. Then cut and glue a small piece of laminate to the exposed edge.

Scribe the overhang

Set your scribe to the overhang dimension. Use this setting to scribe the left side of the top for the return.

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Step 16

Mark the left side of the countertop

Scribe the left side of the top, then cut along your mark with a handsaw, leaving the front edge to nestle around the end panel and create a notch return.

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Step 17

Test fit the countertop notch

Check the cut for fit and sand if necessary. Use contact adhesive on the exposed notch edge and on a small piece of laminate. Once the adhesive is dry to the touch, press the laminate piece in place and file the edge for a clean, precise fit.

Although we made the countertop flush with the cabinet side (to accommodate the range), you may have to adjust your scribe to allow for an overhang.

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Step 18

Attach the countertops to the cabinets

Screw the countertop to the cabinet sides using 1-1/2 in. steel angles with 5/8-in. long No. 8 screws. For a tight fit, screw the angles to the cabinet first and then draw the top down to meet the steel angle with the second screw.

Use as many angles as it takes to get a solid installation. Figure on using four every 3-ft.

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Step 19

Caulk along the backsplash

Pull the colored silicone caulk tube nozzle in one continuous motion along the seam between the backsplash and the wall. Use just enough to fill the gap, then smooth the bead with a moist rag. Use a color-matched siliconized latex caulk for best results. It’s paintable and cleans up with soap and water.

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Step 20

Caring for your new countertops

To get the most life from your new countertops, follow these simple rules:

  • Never use the countertop as a cutting board.
  • Never use bleach or abrasive cleaners. Instead, use products like Fantastic, Formula 409 or Pine-Sol applied with a soft cotton cloth.
  • Avoid setting anything hotter than 140 degrees F. on your countertops. You could burn the laminate or break the glue bond below.