Create Sink Cutouts in Solid Surface Countertops

By
Lee Wallender
Lee Wallender
Lee Wallender

Lee has over two decades of hands-on experience remodeling, fixing, and improving homes, and has been providing home improvement advice for over 13 years.

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Updated on 09/23/22
Reviewed by
Kelly Bacon
Kelly Bacon
Reviewed by Kelly Bacon

Kelly Bacon is a licensed general contractor with over 40 years of experience in construction, home building and remodeling, and commercial building. He is a member of The Spruce Home Improvement Review Board.

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Fact checked by
Jessica Wrubel
Jessica Wrubel
Fact checked by Jessica Wrubel
Jessica Wrubel has an accomplished background as a writer and copy editor, working for various publications, newspapers and in public libraries assisting with reference, research and special projects. In addition to her journalism experience, she has been educating on health and wellness topics for over 15 years in and outside of the classroom.
Learn more about The Spruce's Editorial Process
Kitchen sink

 

Vedrana Sucic / EyeEm / Getty Images

Project Overview
  • Working Time: 30 mins - 1 hr
  • Total Time: 30 mins - 1 hr
  • Skill Level: Intermediate
  • Estimated Cost: $10

True, full-scale Corian or other solid-surface brand counters nearly always turn out best when certified fabricators and installers do the job. But as a do-it-yourselfer, you can produce a pretty good small solid-surface countertop on your own for bathrooms, bars, or small kitchens.

After you cut the material down to size, you will need to make a more complicated inside cut for your sink.

With a little prep work, it is easy to make a cutout for a top-mount sink without special fabrication tools or a router. All you need are common shop tools and some patience.

Tip

Rotary cutting tools are not mentioned in the Corian Fabrication Manual as being a recommended tool, yet they will work for this purpose. DuPont (and all other makers of solid surface counters) recommend against tools, like jigsaws, that create excessive vibration. Be aware that besides slower cutting, the price you pay for using a rotary cutter is that you might run through two or three blades per sink cutout, which is why we recommend having a few extra on hand.

What You'll Need

Equipment / Tools

  • Rotary cutting tool
  • Extra blades for rotary tool
  • Cutting guide track

Materials

  • Painter's tape
  • F-type clamps

Instructions

  1. Create Sink Outline on the Counter With Painter's Tape

    Lay the sink facedown on the solid surface. Draw an outline of the sink or, as shown here, mark off the outline with painter's tape. Be precise about this, as errors will become magnified with the next few steps.

    Once you have created the outside outline, you will need to create another outline. This second outline will be just inside the previous one. All sinks have different specs. With the 15x15 bar sink shown here, the inner outline should be 3/8 inch farther inward.

    Mark off this second inner outline with painter's tape.

    Create Tape Outline For Sink on Corian
    The Spruce / Lee Wallender

  2. Drill Two Pilot Holes Per Straight Side

    Think of your sink cutout as happening in two phases: straight lines and corners. You'll cut straight lines first, corners second.

    Press four tabs of painter's tape down on each corner at a 45-degree angle. The purpose is to preserve this area for your future corner cuts.

    Because rotary cutting tools are drills, you can drill straight into the solid surface material. Drill two pilot holes per side.

    Drill Pilot Hole At Each End of Sink Outline
    The Spruce / Lee Wallender

  3. Clamp Down Your Cutting Guide Track

    Rest your rotary cutter on the solid surface material, with the blade extended into one of the pilot holes. Place your guide track (fence) next to the rotary cutter.

    Clamp down the fence at this spot, with the fence touching the guard of the rotary cutter. Repeat for the second pilot hole on that intended line. Readjust the first clamp if necessary.

    Tip

    There are numerous ways to create a straight, rigid edge to serve as your cutting guide track, or fence. One easy (but expensive) way is with metal cutting guides, such as the Empire 98-Inch Cutting Guide. But you can use any straight, rigid material that will keep your cuts on track.

    Set Guide Track In Place With Clamps
    The Spruce / Lee Wallender

  4. Make Your Straight Cuts

    Power on the rotary cutter. Move the cutter slowly along your fence, starting at one pilot hole and ending at the next one. Let the rotary cutter "tell you" how fast you can move; do not rush.

    Warning

    Wear eye and hearing protection when cutting any solid surface counter material. A respirator is also recommended, as melting solid surface materials can give off noxious fumes.

    Run Cutting Tool Along Guide
    The Spruce / Lee Wallender

  5. Make Your Corner Cuts

    With four lines cut, you now must cut the inside corners. DuPont recommends that the inside radius of your corner be no less than 3/16 of an inch (5mm).

    You can trace this out with a coin or you can just eyeball it as you cut. Since the lip of the sink will cover the corners, appearance does not matter.

    Be sure the cut-out and top are supported before making the last corner cut. Allowing it to just drop could cause the top to break or crack when the cut is far enough for gravity to pull the cut-out down.

    After the last cut, the inside cutout will drop. If solid surface debris is clogging any of the cut lines, lightly run the rotary cutter through that line to remove the debris.

    Now you've just proven to yourself that you really can tackle a fairly involved home project by yourself. Congratulations!

    Stop Straight Lines Before Corners
    The Spruce / Lee Wallender