I would like to make a computer desk with the top made out of Corian. I would consider other materials like granite, marble or, quartz too but I think Corian would be best but I am not sure. Either way I would like to use a solid material for the top staying away from wood/veneer or laminate. The top would be about 4.5 feet long by about 23 inches wide having a gentle curve on the front. I was hoping to make a template or AutoCAD file of the top’s shape for a supplier to work from. I went to Home Depot and learned that they (or their suppliers) will not sell just the material without installing it too. This seems to be what I see on line, too. The questions I have are:
1. Does anyone know a source to use for this? This could be either on line or, if you happen to know a place locally in the Fort Worth/Dallas area.
2. Does anyone have other suggestions as to what materials are out there to use?
3. Can Corian be purchased un-finished and cut to size at home including finishing the edges (the curved front and round over) at home? I think I remember a FWW article about this.
Any suggestions are welcome.
Replies
The sale of "raw" Corian, except in fairly small pieces, is restricted by the manufacturer (DuPont). This is for a variety of reasons, including warranty issues (the product carries a pretty extensive warranty, and they don't want a yahoo installer coming along and making them have to pay for his mistakes). From what I understand, certification is a rather painful process, and completely out of the question unless you run a cabinet shop.
I don't know of any Corian-like materials that are freely available in countertop-sized sheets. One alternative is PaperStone (http://www.paperstoneproducts.com/), which is a paper/resin material. You can get PaperStone in full sheets, but not all of their dealers will sell it that way, so you have to ask around, and you may end up paying a significant amount for shipping.
I've worked with PaperStone a little bit; it's pretty nice, but like Corian it's pretty easy to scratch, and it won't take a polish. It's very easy to renew with a random-orbit sander, however.
-Steve
You could talk to a Corian dealer. He has the tools to cut, trim, and sand the Corian to your specifications which would be difficult for most woodworkers. He would probably insist that you supplied him a full-sized template and some sort of structure to bond the Corian onto (I would think breakage is a huge worry for them).
Or get a competitors man-made surface (I wouldn't want to try and cut / trim / sand a curved granite desk top).
Good luck. Post a pic of your design.
The Wood Loon
Acton, MA
For years I had been installing Corian and bought it from the supplier until they told me I had to take a class. That was about 1992. Then I bought Surell from Formica. Now I have gone to all granite because the price is so close now.
I picked up some sink cutouts from a local source that installs kitchens at a good price. As Steve said getting a large piece is not easy. Art Specialities in Lancaster, NY did sell small pieces to the public but the link I have no longer works.
Corian can be cut with carbide bits, it is just a plastic. I enjoyed cutting and routing it. It would produce ribbons when routing. If you drill it use a very slow speed and take it easy, if you don't it will melt. I even enjoyed the plastic smell when machining but some people do not.
Life is what happens to you when you're making other plans .
"Life is not a success only journey." Dr. Phil
As Steve said, the sale of Corian is limited to certified installers. Some of the other brands might be available with out certification.
You might want to build the desk, with an undersized, removable plywood top. You could then have a shop build the top on your plywood for you to install.
I just Googled, "corian installer Dallas", and got a bunch of hits.
Call around, one of them will make you a top to install your self.
I have a friend who with his bro in law became certified Corian installers. Actually, I think his in law took the course and then taught my friend. The course takes like two days. As I understand, you can tool it and weld two pieces together. It can be very attractive but is expensive.
Corian is a specific brand. Dupont's patents ran out, and now many other manufacturers make similar products. The generic term is "solid surface". Dupont is still trying to sell only to certified installers, but other manufacturers are not as rigid. You may be able to find solid-surface suppliers in your town who will sell to you.
Here's a link to an online outfit which seems to be willing to sell solid surface to anybody. http://solidsurface.com/
I found the same ludicrous policy whe I wanted to by some Corian for end tables. Ended up buying Wilsonart solid surface from a local place without any hassles about licensing or classes.
If you build it he will come.
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