How To Build a Laminate Counter

Building your own laminate countertop can add a stylish touch to your kitchen without at a fraction of the cost of professional installation. If you gather the right tools and focus on the correct cutting and application techniques, you can achieve professional-looking results. Read our guide below to lean how to build a laminate counter, and watch the video above for tips from This Old House general contractor Tom Silva. 

Preparing the Countertop Base

The first step in building a laminate countertop is to create a sturdy plywood base. Silva recommends using AC plywood because it has one smooth side and contains exterior-grade glue, which makes it resistant to moisture and steam.

1. Measure and Cut: Cut the 5/8-inch AC plywood to fit your cabinet dimensions. Allow for a 1-inch overhang at the front and a 1/4-inch overhang at the ends.
2. Backsplash Fitting: Cut separate pieces for the backsplash using the same plywood.
3. Test Fitting: Test fit the plywood base on top of the cabinets and make sure the elements fit properly.

Building Up the Countertop Edge

A thicker countertop edge adds a touch of elegance and durability.

1. Create Build-up Strips: Cut 4-inch-wide strips of plywood for the build-up strips.
2. Attach Strips: Use wood glue and 1/4-inch crown staples to attach these strips around the perimeter of the countertop’s underside.
3. Trim the Edge: Trim a block plane so that the build-up strips are flush against the counter’s edges.

Cutting and Applying the Laminate

Be especially careful when cutting and applying the laminate. Precision here is key. 

1. Rough Cut: Rough cut the laminate sheet so that it’s slightly larger than the countertop dimensions. This will allow for some working room.
2. Trim to Fit: Use a laminate router with a flush trim bit to cut the laminate to the exact size of the countertop.
3. Prepare Edges: Cut 2-inch-wide strips for the counter edges and 1-inch strips for the backsplash edges.
4. Apply Adhesive: Apply contact cement to the laminate and the countertop surfaces and wait until it becomes tacky.
5. Laminate Positioning: Carefully position the laminate and press it down using a J-roller so that it adheres evenly.
6. Final Trim and Sanding: Use the router to trim excess laminate and sand the edges flush for a clean finish.

Silva recommends using a 5-foot-wide laminate sheet, which eliminates the need for seams on most countertops.

Edge Order Matters: Each piece of laminate should be cut larger than the surface it covers and then trimmed flush with a small router and a file before the next piece goes on, ensuring a tight seam at all corners. The side edges go on first, then the front edge, and finally the top. This layering sequence hides visible edges and creates clean, professional-looking joints.

Incorporating a Sink into Laminate Counters

Plan carefully as you prepare your sink, and make precise cutouts. This will help to prevent future issues.

1. Template Placement: Position the sink template on the countertop and trace its outline accurately.
2. Cut Sink Opening: Use a jigsaw to carefully cut out the sink opening without damaging the surrounding surface.
3. Seal and Secure: Apply a bead of silicone adhesive around the sink cutout and lower the sink into place. Secure it according to the manufacturer’s instructions.

To support the cutout piece and prevent it from dropping or binding the saw blade mid-cut, lay a scrap of wood a few inches longer than the cutout across the sink area and screw through the scrap into the waste piece. This keeps the cutout from falling prematurely and ensures a clean, controlled cut all the way around.

Pro Tip: On the This Old House project at the Arlington House, Norm demonstrated a critical detail when cutting the sink opening: “In most cases, you do not want to cut these corners to a point… Because that will cause a stress point in this counter, and very likely, the laminate will crack after a while.” Instead of cutting square corners, drill a radius hole at each corner before making your jigsaw cuts to relieve stress and prevent cracking.

Attaching the Backsplash

A backsplash adds a polished look to your kitchen and protects walls from water damage. Follow the steps below.

1. Adhesive Application: Apply silicone adhesive to the rear edges of the counter where you plan to place the backsplash.
2. Position Backsplash: Position the laminated backsplash pieces along the countertop edge.
3. Secure Backsplash: Drive 2-inch screws in from underneath to secure the backsplash firmly to the countertop.
4. Caulking: Caulk the seam between the backsplash and countertop to create a watertight seal.

Enhancements and Features for Your Countertop

Adding special features such as custom edges and inserts can enhance the utility and aesthetic appeal of your countertop.

Integrated Cutouts and Inserts

Incorporate special cutouts and inserts according to your kitchen’s needs. Consider the options below.

• Chopping Board Cutout: Add a slide-in chopping board that you can easily access.
• Cooktop Fit: Make sure there’s a precise cutout for your cooktop.
• Utility Inserts: Integrate steel inserts on which you can safely set hot cookware.

Custom Edges and Accents

Customize the countertop edges with the elements below for a unique design.

• Bullnose Edge: A rounded bullnose edge gives a soft, contemporary look.
• Metal Accents: Use metal strips or accents for a modern flair.
• Wood Inlay: Add decorative wood inlays for an elegant touch.

Final Installation

Once you’ve prepared all of your components, you can proceed to the final installation of the countertop. Follow the steps below.

1. Adhesive Application: Apply silicone adhesive to the cabinets’ tops so that they firmly adhere to the countertop.
2. Position Countertop: Carefully lower the countertop into place. Check for level alignment.
3. Secure Countertop: Secure the countertop to the cabinets according to local building codes.

Pro Tip: After securing the countertop, wipe away any caulk that squeezes out at the seam with a wet finger to create a smooth seal between the two pieces of laminate. Then caulk wherever the countertop directly meets the wall and smooth that bead for a finished look.

Technique Detail: Rather than using silicone adhesive alone, run a bead of caulk along the tops of the cabinets and on the sides of the counter where any two pieces will meet. Then, from inside the cabinet, drive 1⅝-inch screws up through the mounting blocks in the cabinet corners and into the counter. If connecting two countertop sections, drive ¼-inch screws through the extended strips to fasten the two sections together.

Tools: