problem trimming formica - Router Forums
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post #1 of 11 (permalink) Old 11-12-2014, 08:14 AM Thread Starter
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Default problem trimming formica

I'm building some shelves and was using the bosch 1618evs mounted on my router table. I am laminating all of the legs which are 2" oak then cutting a 45 deg angle on all 4 sides. The problem is when I ran the piece (all edges counter clockwise), I'm getting some chipping on the edges of the formica. I have the speed cranked up to the max, 25k rpm. The 45 deg is a new Whiteside with a 1/2 shank.
On my test piece I started at about 4 then worked up to the max. The chipping decreased but I still didn't get a clean cut. Would anyone have any ideas on what's causing the chipping??
Thanks
Ken
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post #2 of 11 (permalink) Old 11-12-2014, 08:34 AM
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Hard to say, maybe crummy laminate. However, this cut, as light as it is, can be climbed.
The backwards feed may eliminate it.
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post #3 of 11 (permalink) Old 11-12-2014, 08:43 AM
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Is it possible you might be taking too much off at one time...? Or maybe feeding too fast...? Or both...? Is the Formica on the leading or trailing edge of the cut...?

Welcome to the forum, Ken...

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post #4 of 11 (permalink) Old 11-12-2014, 10:46 AM
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Welcome to the forum Ken. I've usually only had problems when the laminate isn't securely glued to the substrate.

Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
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post #5 of 11 (permalink) Old 11-12-2014, 11:22 AM
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Hello and Welcome to the forum Ken.

Looking forward to your participation.
Filling out your profile to include (first name,tools and short bio is strictly (optional )but does help members to better relate to each other.
Thank You John
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post #6 of 11 (permalink) Old 11-12-2014, 08:18 PM
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Not my first choice in a router bit to trim formica\melamine. I would use a down cut spiral bit to trim the laminate.

You may have to make a jig to orient the leg at a 45 degree to accomplish the cuts you need.


Just remember what my father always said, " Half the people in this world are below average!", and everything in life will make a hellova lot more sense.
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post #7 of 11 (permalink) Old 11-13-2014, 11:21 AM
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Hi Ken ,welcome,
I don't understand, are you taking a 2"X2" leg, laminating all 4 sides with p-lam and then chamfering the corners with a 45 degree chamfer bit? If that is the case you will be cutting both the upper and lower P-lam at the same time. Are you getting chipping on both the top and bottom? if this is the case I think you are using the wrong bit. You might try making a jig to lay the leg at 45 degrees to a straight bit on a router table. A solid carbide bit might work best.

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post #8 of 11 (permalink) Old 11-13-2014, 04:14 PM
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Quote:
Originally Posted by kln4 View Post
I'm building some shelves and was using the bosch 1618evs mounted on my router table. I am laminating all of the legs which are 2" oak then cutting a 45 deg angle on all 4 sides. The problem is when I ran the piece (all edges counter clockwise), I'm getting some chipping on the edges of the formica. I have the speed cranked up to the max, 25k rpm. The 45 deg is a new Whiteside with a 1/2 shank.
On my test piece I started at about 4 then worked up to the max. The chipping decreased but I still didn't get a clean cut. Would anyone have any ideas on what's causing the chipping??
Thanks
Ken
wrong bit...
you need one designed/engineered for laminate...

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post #9 of 11 (permalink) Old 11-17-2014, 04:29 AM Thread Starter
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Thanks for all replies.
I figured out the problem
1. I forgot to set the bosch to max speed. Once I set it to 6 the chip problem went away.
2. I forgot to roll my edges before cutting the 45, so every time I ran the piece it I got some minor chipping at the top and bottom of my test pieces.

I am using formica brand, and the "odorless" glue. After I roll it still need to set for about half an hour then I run the piece with the edge cutter first. I put in 45 cutter then run the pieces, no more chipping.

PS: It took me awhile to figure out how to get on the board. When I first registered I cleared my history, all of it, to get rid of tracking cookies. I blew away everything.
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post #10 of 11 (permalink) Old 11-17-2014, 11:00 AM
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It has has to be stuck down good and tight or I think it starts to vibrate ansd it can chip when it does that. You also want to make sure that the overhang on the lam is less than half the diameter of the bit or it can shatter chunks off from that too. I've done quite a few bevels on counter tops to expose a hardwood edge and had no problems if I followed those rules.

Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
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