How to Seam a Corian Countertop

A Corian countertop is found in many kitchens, and it is made of acrylic, that is molded to a particular design. Most makers of this countertop recommend their professional expertise in joining the corners, since the process is significantly different from seaming ordinary countertops, which are usually laminated. However, it is possible to do this process by yourself, and you don’t need a professional in order to seam your Corian countertop. Below is a guide to help you with the process.

Step 1: Preparations

Clean the countertop edges and the seam support strip, using a rag wet with alcohol. This prevents dirt from sticking to the strip later on, in order to make it stick more firmly. Once you have the countertop clean, evenly apply some silicone caulk on the top edges of the cabinets. Carefully place the seam support strip under the seam.

Step 2: Placing Wood Blocks

Get some epoxy, and apply an even layer on the edges of the Corian countertop, at the points where the 2 sides will be connected. Apply also some epoxy on the support strip that you placed earlier. Then, apply some glue on the wood blocks and place 1 block on each side of the 2 pieces being joined together. Let the glue set, so the blocks will be firmly in place. These blocks serve as a buffer, when the seams are pressed to the countertop. They prevent damage to the seams, since they will be taking the pressure. If you use the clamps directly on the Corian countertop, it will damage the surface.

WARNING: Some forms of epoxy release toxic fumes, so be sure your work area has proper ventilation before you start applying it. If you have a history of respiratory issues, wear safety glasses and a face mask while working with it.

Step 3: Press the 2 Parts Together

Get the cabinet clamps and use them on the wood blocks, in order to press the 2 parts of the Corian countertop together. Open up the clamp, and then clamp down on the wood blocks as you tighten it. Some of the epoxy will probably leak out, but leave this for now. Let the epoxy set up, until the seams are firmly in place. Wait for a couple of hours before proceeding. It is also suggested to follow the recommendations of the epoxy, as to how long you should leave it to dry (in some cases, this may mean waiting 24 hours).

Step 4: Remove the Wood Blocks

Once the 2 parts have been bound together, remove the clamps and pour alcohol around the wood blocks. This should loosen the glue, in order to remove the blocks. Remove the wood blocks once the glue has softened. Do this carefully, to prevent damage to the countertop. Wipe up any excess alcohol that you poured on the wood.

Step 5: Sand the Seams

After removing the wood blocks, sand the seams, using 100-grit sandpaper. Use 150-grit after this, and then 200-grit, until the seams are smooth and the epoxy is removed. Be careful not to sand the seams too much, in order to avoid making them appear too obvious again.

WARNING: If you use a machine sander to sand the seams, wear a face mask and safety glasses to keep particles out of your eyes.

Step 6: Polishing

Get the orbital sander, and attach a buffer pad to it. Turn it on and buff the seams to a nice shiny finish. Apply a firm and even pressure on the seams, and make sure that you cover everything. You now have the seams of your Corian countertop.