I recently tried a different method for building a laminate counter. I bought the material already laid up (11/16" particleboard, HPL 1 face.) With the sheet face down on the CNC, I through-cut the counter outline, leaving the finished edges 5/16" larger than their finished dimensions. I then raised the bit the thickness of the laminate, and did another pass on the finished edges, taking off 5/16". The laminate on the face of the panel (which will be the top of the counter) was now overhanging the finished edges 5/16".
I carefully ripped material for finished edges and glued them on. Top laminate was now overhanging finished edges by 1/4". I trimmed all, filed, and the counter came out nicely. The weak link was gluing the front strips on. I need a neater way to do this. I just brushed on the contact cement, which was slow and messy, particularly where you're trying not to douse the top laminate where it overhangs the edge. I tried several layers of Fastcap's Speed Tape, to glue the edges on a sample piece, but it didn't bond well enough to the substrate. I think that spraying might create even more of a mess than brushing. Assuming I haven't thoroughly confused everyone, I'm open to suggestions on how to improve this process, as I have quite a few counters to make.
From contributor A:
Assuming your front edge is laminate as well, you should use spray-on contact adhesive. I buy small canisters from the laminate supplier. The gun and hose stay on the can so there is no clean up. Once you try spray-on you will never want to brush on contact again.