Using Melamine

Melamine is the professional cabinetmaker’s best friend. Build a
cabinet with it and you have a complete, durable interior that requires
no sanding (yes!) and no finishing (oh, yeah!). Pros often build whole
kitchens out of melamine and then dress the boxes with plywood end
panels and solid-wood fronts. The bright melamine cabinet interiors are
easy to search, stain resistant and tough as nails. Entertainment
centers and home office, laundry-room or mudroom cabinets are also made
with melamine. Most home centers carry melamine shelving with the edge
banding already on. Just buy or make shelf supports and you’re in
business. Melamine has found a home in many a woodshop. The durable,
slick surface is perfect for jigs, fences, outfeed tables and router
tables. I use it in my shop as an assembly table cover. Glue drips pop
right off and the slick surface makes it easy to slide around heavy
assemblies. It’s not as durable as plastic laminate for high-wear
surfaces such as countertop and desktops, but it’s plenty tough for
shop use.Still not sold on melamine? How about saving money? It’s about
half the cost of birch plywood. Not only that, but you get better yield
from a sheet of melamine than from veneer sheet stock. That’s because
you don’t have to worry about grain direction. Better yield at a lower
cost—you save both ways. Here are some tips on how to make this staple
material of the modern cabinetmaker work perfectly for you!

Go Beyond Basic White
White melamine is by far the most common, but basic colors, like
black, almond and wood grain, can be special-ordered from most home
centers or lumberyards that carry the white. Melamine comes in a wide
range of thicknesses. Home centers not only carry 3/4-in. and 5/8-in.
sheets for cabinet construction and shelving, but they often have
1/2-in. for drawer parts and 1/4-in. stock for backs and drawer bottoms.

Stop the Chip-Out Monster
Chip-out on the bottom edge is a common problem when you use a
general-purpose blade to cut melamine. Sometimes one rough edge doesn’t
matter, but when you need a perfectly clean edge on both sides, you
have a couple options. The first is to make a 1/16-in.-deep scoring cut
on the bottom of the piece (see photo, below). Turn the saw off and
crank up the blade to finish the cut. The result is a perfectly clean
cut on both surfaces. The second solution is a laminate-cutting blade
(above), which gives you perfectly clean edges on both sides, without a
scoring cut. If you cut a lot of melamine, these blades are well worth
the investment.

Sources
Woodworker’s Supply, (800) 645-9292, www.woodworker.com, Freud LU97 double-sided laminate blade, #117-386, $90.

Wear Gloves!
Gloves are a must when handling large sheets of melamine. We
recommend a pair of Kevlar® gloves. Kevlar is designed to protect the
user from slicing cuts. Surprisingly, they’re inexpensive ($5) and the
rubber dots or stripes help you get a grip on the slippery melamine
surface.

Source
All Safety, Equipment & Supplies, (888) 739-1080, www.AllSafetySupplies.com, Kevlar gloves, #SS-GLK600PD2, $5.

Use Your Router To Drill Holes
Drilling for adjustable shelves can be a problem in melamine. A
sharp brad-point bit will make a clean hole, but the melamine is hard
on the cutting edges and a typical bit will quickly dull. Production
shops use special carbide-tipped bits that are expensive and hard to
find. For the weekend builder, the best way to drill holes in melamine
is to use a router. A simple jig and a plunge router with a 5/8-in.
guide bushing is the way to go. Use a 1/4-in. carbide down-spiral bit
for flawless holes. The jig is simply a piece of 1/2-in. plywood with a
series of 5/8-in. holes spaced at 2-in. intervals. Clamp the jig flush
with the case side, set the bushing in the first hole and plunge.
Repeat the process until all the holes are drilled.

Source
MLCS, (800) 533-9298, www.mlcswoodworking.com, 1/4-in. spiral down-cut bit, # 5177, $14.

A Tongue Makes Dado Joints Easier
Routers are great for cutting dadoes in melamine, because it assures a
chip-free cut. Unfortunately, melamine is about 1/128-in. over 3/4-in.
As a result, if you try to use a 3/4-in. router bit to cut a dado,
it’ll be slightly undersized—not a pretty picture come assembly time.
You can get around this by making a 1/2-in. dado and creating a
1/2-in. tongue on the ends of the shelf with a rabbeting bit.

Reinforce joints with melamine glue
Typical wood glue won’t bond at all to melamine’s slick surface. That
leaves you with a weakened glue joint where melamine meets
particleboard. Fortunately, you can buy specialized glue that will bond
melamine to a porous surface like particleboard. This is especially
critical on more delicate joints, for instance, those used to construct
a drawer.

Source
Woodworker’s Hardware, (800) 383-0130, www.wwhardware.com, 8 oz.
RooClear melamine glue, #R8012, $4, 16 oz. Titebond Melamine Glue,
#F4014, $7.

Cover Unsightly Holes
The easiest way to cover exposed screw heads is with Fast Cap
self-stick caps. These discs come in typical melamine colors and
they’re a cinch to apply–just peel and stick.

Source
McFeely’s (800) 443-7937, www.mcfeelys.com, 52 white PVC peel and stick caps, #FCS-6100 $2.

Throw Away Your Iron
Melamine needs to be edged for a finished look. You can use iron-on
edging, but self-stick edging is faster, easier and incredibly strong.
Just peel, stick and give it a pass with a wood block or roller to push
the adhesive into the particleboard. Maximum strength is obtained in a
week.One swipe with a double-sided edge trimmer cuts the tape flush.

Source
Woodworker’s Hardware, (800) 383-0130, www.wwhardware.com, 50-ft. roll
of white 15/16-in. self-stick tape, #FCFESP 1516 50WH, $14,
Double-sided hand edge trimmer, #VIAU 93, $13.

Flush-Fit Caps Appear Invisible
A flush-fit screw cap looks a whole lot better than the surface-applied
caps. Plus, they are less prone to getting knocked off. The FlushMount
carbide drill bit cuts a shallow 9/16-in.-dia. countersink for the
self-stick cap. An adjustable brad-point bit protruding through the
center of the carbide bit drills the pilot hole. Both bits can be
adjusted for depth of cut. Just drill, screw and cover. The caps are
almost invisible. The same system can be used on wood-veneered sheet
stock.

Source
McFeely’s (800) 443-7937, www.mcfeelys.com, FlushMount carbide drill
bit, #FCS-6050, $40, 52 white PVC peel and stick caps, #FCS-6100 $2.

Repair, Don’t Despair
Small nicks and gouges are easy to fix using SeamFil. It works just
like wood filler but it’s designed for plastic. Just work a little into
the wound and scrape it flush using a putty knife. After the filler
dries, use a utility razor to remove any excess. It makes a quick, easy
repair that’s only noticeable at close range.

Source
Woodworker’s Hardware, (800) 383-0130, www.wwhardware.com, SeamFil,
1-oz. squeeze tube:white #K901, black #K914, almond #K941, $4 ea.