Expert: Jamie Yocono - 9/28/2008

Question
I am making an outfeed table for my table saw and will be covering it with some willsonart formica. I need to cut two dados for the miter slots. Should I cut the dados first then cove and trim with my trim router or can I cover it first then cut the dados on my table saw? I am not sure if it would chip the formica if I did it this way. Also what would be better mdf or nice grade plywood?

Answer
Hi Cameron,

I would machine the dados after you've glued down the plastic laminate. I've routed plastic laminate many times, it doesn't chip as long as your cutter (bit) is sharp. I think doing it the other way could give you a big headache - what if your dado isn't deep enough to clear the bearing?

Personally, I prefer MDF over plywood, it just seems like it stays flatter. The plywood I've worked with lately all seems to curl up on me, which is a pain. But if you use MDF, make sure it has some sort of apron underneath to keep it flat.

But I have a different suggestion - about material. See, using plastic laminate (formica) means you'll need a sheet of MDF, contact cement, rollers or brushes, the laminate itself, and a flush trimming bit. Technically, you're supposed to cover both sides, to keep it from curling, so that's a lot of work and money!

Rather than going through all the steps to spread the glue on everything, then align and adhere it, why not consider just using a melamine covered sheet of MDF?

Just off the top of my head, I'm thinking the cost would be less than half, and it would certainly be less work. Melamine would be thinner than plastic laminate, but I've used it for many tabletops around my woodshop. It's so cheap that when it gets really banged up, I just replace it. It's easy to clean, and glue pops off it quite nicely, too

In fact, if you have a good plywood supplier, they might be able to steer you toward some overstock sheets. My last plywood supplier had some melamine sheets left over from a batch that someone had ordered, and then never picked up. I bought about 40 sheets for a dollar a sheet. It was a funky gray color, but I'll tell you, it really came in handy.

Just a suggestion!  Good luck, hope this helps,

Jamie Yocono
Wood It Is! Custom Cabinetry
Las Vegas, NV
www.wooditis.com