Coving Solid Surface Counter/Backsplash Joints

Details about how to efficiently get nice results in a solid surface cove joint. March 28, 2012

Our shop is somewhat new to the coving methods. I would appreciate some suggestions to streamline this process so we can keep moving forward.

Forum Responses
(Laminate and Solid Surface Forum)
From contributor E:
Betterly router with a sharp bit is the way to go.

From the original questioner:
We are currently using their air glide coving router. What are your sanding methods?

From contributor E:
Sand the inside of the cove by hand, starting at 80gt all the way to 220gr, then sand right up to the cove when sanding the surface and the splash itself. Then hit it with a white Scotch-Brite just before you do the surface and the splash. Here is one we just did last week.

From the original questioner:
Can I ask how many hours you had total on that top? What sanders do you use? We use a Festool Rotex, 5" Dynabrade and the small 3" Dynabrade.

From contributor E:
I just use the Festool. I have a pile of the Dynabrades - they just don't cut it. I fabbed that top start to finish myself in about 10 hours. It is about 20 feet of cove on that top and an ogee edge.

From contributor J:
Wow, 10 hours sounds great and the top looks great too. I don't think my guys could get it done in 10; maybe 15-18 hours.

From contributor E:
Experience has a lot to do with it. I have been doing this for 15 years now. I fab everything - laminate, solid surface, engineered stone, granite, marble, onyx and wood, when the economy went south. I paired up with 3 others and started a small shop. The 4 of us have been able to weather the storm and cater to the high end clients.

I did that in 10 hours by myself. If you have 2 guys working on it for 10 hours, you have 20 hours invested. That 10 hours is the lower part only - I had another 6-8 on the upper. A lot of that was sanding the ogee.

From contributor F:
The Betterley system is definitely the way to go, but what were you using 80g on?

From contributor L:
We have been having excellent luck with Lowes or Menard air sanders to grind with. If we start with those, then go to a Fein. We have excellent results. We hate the Dynabrades for solid surface, too.