Replies

1. 
   RalphBarker | Mar 02, 2011 09:59am | #1

   phenolic vs. Formica

   First, it appears there are two grades of phenolic ply available - a construction grade used for concrete forms and such, and a better grade made with Baltic Birch Ply. My understanding is that the construction grade applies the phenolic film with a glue, while the better grade impregnates the phenolic into the top surface with a heat process.

   For maximum durability, I'd think a plastic laminate (Formica being one brand) would be better, since it is considerably thicker. Many recommend laminating both sides of the substrat (BB ply or MDF) to avoid warping, while some assert this is not necessary (as with kitchen counters). For a router table, where flatness is essential, I'd do both sides at the same time.

1. 
   AutumnWoods | Mar 02, 2011 12:28pm | #2

   Laminate both sides

   Unless you have something totally rigid to attach the top to (a torsion box or sturdy frame) I would laminate both sides.  I've installed kitchen countertops for a long time and never known one to stay flat - at least to the level of accuracy you would want a router table to be.  And I would second the notion of using formica.  It's not hard to apply, I like it better than melamine, and I've never been able to find phenolic plywood in my area. 

1. 
   RalphBarker | Mar 03, 2011 09:57am | #3

   phinding phenolic

   There have been several threads here about finding phenolic. Bottom line, it's not a commonly stocked item, particularly if you're looking for the better grade (real Baltic Birch ply with impregnated surface) in full sheets. Woodcraft and Rockler sometimes have smaller pieces (24"x36" or so).