Corian/Cherry Kitchen Counter

Instructions

Mill the rear lumber to size (slightly oversize it for now). Add chamfer to the rear hardwood using a table saw, such that the bottom of the chamfer is aligned to the thickness of the corian. Ensure the Corian is square - size it to match the rear lumber length. Cut the bottom ply to match the corian+hardwood that will go on top of it. On bottom side of corian, apply shaper tape, and create a grid on Origin. Drill the 8x 5.16mm Dia Holes for the helicoils: https://amzn.to/37qHpX0 (helicoils). Tap the holes using the tap that comes with the helicoil kit. Install the helicoils into the Corian. Use a hammer and punch to knock out tangs on the helicoils - be careful - this can break through the thin corian under the blind hole. Don't hit it too hard. On bottom side of the ply, a make grid referenced off same corner as corian was. Cut the counter-sunk hole pattern. Attach the rear hardwood to the ply. I did this by using Origin to install alignment dowels in each part, and then added wood glue and clamped. You could also screw together from the bottom. cross-cut glued ply+hardware to final length on table saw (make their edges line up perfectly) Temporarily install the corian to the rest with the screws: https://www.mcmaster.com/92235A214/) If corian length/width is not perfectly matched to wood, trim it down with table saw or large belt sander. Unscrew corian top Sand and finish wood elements Re-attached corian top with screws Apply silicone caulk to the seam between the corian and the rear wood: https://amzn.to/3iyVsju Align hairpin legs to the bottom of the ply, (I made a jig to position them a consistent distance from the corner, by about 1/2"). Drill pilot holes for marked holes from legs, and screw legs in using 3/4" wood screws: https://www.mcmaster.com/91070A199/ Attach the hairpin legs: https://www.diyhairpinlegs.com/collections/sets-of-hairpin-legs/products/set-of-3-rod-hairpin-legs?variant=31987213402174