zfennell wrote:use a router
and buy the same
bit they use for trimming formica countertops.
most anything will cut formica, but its easy to chip and crack if its not well supported
they trim kitchen counters after the formica is bonded in place.
True. If the PVC foam core is not dense enough to act as a guide for the
router it might ba a good idea to replicate the foam outline in plywood
(you could use the wood as a template to cut the foam). Stick the
formica to the plywood with a light-bonding adhesive before shaping it
with the router, then remove it from the wood and glue it to the foam.