I thought I would add the story of the last two days to maybe help someone who may attempt this in the future. I've never used Formica or a router before but I'd say one side was fairly straight forward. The centre pieces are going to be the tricky bit.
So day 1 - Monday
I empited most of the cab again:
Cleared a big space in the garage:
Lightly sanded down the side of the cab with some fine sandpaper just to get rid of any bumps, and brush any dust off:
Formica time!
Unwraped the Formica, and let it flop level:
Then placed the cab on its side and drew round the cab adding an additional 1/2 inch all round:
Then cut it out with a stanley knife and got a basic template. Then brushed down the Formica to remove any dust:
Day 2 - Tuesday
Stuck some glue on both cab and Formica. I used Thixofix Eco which is really good stuff, and non hazardous. I used a foam roller to get a nice even spread. A good idea is to use a new foam roller on both cab and Formica:
Then cut some plastic strips, approx 1/2-1 inch and placed them on the cab so that the two parts do not touch:
Waited until the glue went clear, and then placed the Formica on the plastic strips. Moved into position and then pushed the Formica to the cab using a small wallpaper roller, and went along and removed each strip until the Formica was bonded to the cab:
I then got the router out with the flush trim bit, and cut off the excess Formica. The trick seems to be to let it glide round the cab without applying any pressure. But boy is it messy!
1 side done:
(see above)
Same again tomorrow!
Purity2014-08-19 22:45:11