Building your own custom laminate countertop using sheets of plastic laminate and particleboard offers two advantages: the countertop you get will be less expensive than a custom-ordered countertop, and it will allow you more options in terms of colors and edge treatments. A countertop made with laminates also can be tailored to fit any space, unlike premade countertop material that is a standard width (usually 25").
Laminate is commonly sold in 8-ft. or 12-ft. lengths that are about 1⁄20" thick. In width, they range from 30" strips to 48" sheets. The 30" strips are sized specifically for countertops, allowing for a 25"- wide countertop, a 1½" wide front edge strip, and a short backsplash.
The plastic laminate is bonded to the particleboard or MDF substrate with contact cement, though most professional installers use products that are available only to the trades. Water-based contact cement is nonflammable and nontoxic, but solvent-based contact cement, which requires a respirator and is highly flammable, creates a much stronger, more durable bond.
Fabricating your own custom countertop from particleboard and plastic laminate is not exactly an easy DIY project, but it gives you unlimited options, and the results can be very satisfying.
Tools & Materials
Tape measure
Framing square
Straightedge
Scoring tool
Paint roller
Bar clamps
Caulk gun
J-roller
Miter saw ( as needed)
Compass
Utility knife
Aviator snips
Circular saw
Belt sander
Router ( with bevel cutting bit)
1⁄2" scrap wood
1⁄4" plywood
1 × 4 lumber
3⁄4" particleboard
Sheet laminate
Contact cement
Wood glue
1⁄4" drywall screws
2" wallboard screws
Mineral spirits
Wood filler
Finishing materials
Laminate
Silicone caulk
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