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How to Cut Sink Holes in Corian

Paul Massey

Corian is an polymer-based acrylic that offers the visual appeal of granite or marble, without the weight or higher costs of natural stone countertops. Corian's non-porous, stain-resistant composition makes it easy to work with and, unlike the stone alternative, easy to cut for plumbing or other fixtures. The procedure for laying out and cutting a sink hole is a standard cutting method adaptable to any opening needed in a Corian surface.

  1. Mark the desired lateral center line of the sink location with a tape measure and No. 3 or harder pencil. Use a framing square to extend the center line perpendicular from the front edge of the counter to the backsplash.

  2. Cut out the sink opening of the sink template, using scissors and following the printed instructions using scissors.

  3. Align the sink template on the center line and adjust the front offset recommended by the sink manufacturer. Allow appropriate clearance between the rear rim of the sink and the backsplash to the faucet placement. Once correctly positioned, the template can be temporarily held in place with strips of masking tape.

  4. Scribe the sink cut outline defined by the sink template, using a No. 3 or harder pencil.

  5. Bore a 1/4-inch hole at each side of the sink outline, approximately 1/2 inch inside the pencil line marked in Step 4, using an electric drill. Slow the drill speed as it nears the penetration point to minimize chipping on the underside of the Corian.

  6. Cut the sink hole out of the countertop, using a jigsaw mounted with a fine-toothed down-cutting blade. A down-cutting blade's teeth are cut so that any chipping that might occur during the cutting is on the bottom side of the material. Set the cutting speed to medium-fast and cut slowly to avoid overheating the blade and possibly burning the cut edge.

  7. Remove the sink cutout piece when the cut is completed and polish the edge of the opening, using a orbital sander with progressively finer sandpaper.