Wilsonart Decorative Edge Fabrication Manual. Wilsonart Decorative Edges

Transcription

1 Wilsnart Decrative Edge Fabricatin Manual Wilsnart Decrative Edges BR Revisin

2 Wilsnart Decrative Edges Prduct Descriptin Wilsnart Decrative Edge mldings may well be the best way t attain leading-edge kitchen and bath design withut a leading edge budget. The simple additin f decrative mldings can transfrm an rdinary laminate cuntertp int a real design statement, by eliminating the brwn line and adding literally millins f design ptins. In fact, ur beveled laminate mldings are available in ver 200 slid clrs and patterns. Cascade and Crescent laminate are available in HD, Milan (#52 finish), and Madura (#52 finish) patterns and finishes. Our wd mldings are made f hand-selected slid hardwd. Check availability fr each specific decrative mlding design. The Decrative Edge cncept is a simple ne. S simple that thusands f qualified fabricatrs acrss Nrth America are creating custm lks with laminate-clad Decrative Edge mldings everyday. They are s durable we ve given them a ten-year limited warranty against face edge delaminatin. S if yu re building r remdeling a kitchen r bath, Decrative Edge mldings are the affrdable design ptin yu just can t affrd t verlk. * Bevel Mldings (FE-Flat Edge and SE-Snap Edge): The Bevel Edge creates a sleek, seamless lk. The tw planes f the mlding may be specified with the same laminate as the tp, fr a mnlithic effect, r in crdinating and cntrasting clrs r patterns (chse frm ver 250 Wilsnart Laminates). * Cascade (FE-Flat Edge and SE-Snap Edge): The Cascade Edge pairs a flwing waterfall rll with a straight-edged base fr a lk that is naturally beautiful and impressive. * Crescent (FE-Flat Edge and SE-Snap Edge): The Crescent Edge invites the eye and warms up decr with sft curves at tp and bttm. * Wd Mldings: The Decrative Edge Wd Mldings are the way t add the warm, hand-crafted lk f wd t yur kitchen r bath. They re ffered in three prfiles f standard stck in Red Oak, and Hard Maple. Hwever, any wd species is available. Radius Crner Mldings are available in 2, 4 and 6 in Red Oak and Hard Maple. Radius Crner Mldings and wd mldings can be grved t accept a laminate r metal insert. GUARANTEED TEN YEARS Unlike sme mlding prducts, laminate-clad mldings are made with medium density fiberbard (MDF), t which decrative laminate is bnded. Because f this assembly technique, it s practically impssible fr the face edge f the mlding t delaminate. In fact, we have s much cnfidence in the perfrmance f laminate-clad mldings we back them with a ten-year warranty against face edge delaminatin. See yur distributr f Wilsnart prducts fr cmplete details. 2

3 Wilsnart Decrative Edges Safety Strage SAFETY Safety shuld be a critical cncern fr any fabricatin shp. Gd safety practice can lwer yur insurance rates - but mst imprtant, they will keep yu and yur clleagues injury-free and n the jb. Wear safety glasses with side shields when yu are cutting r ruting. D nt take chances with flying chips and fragments. The edge f Wilsnart Laminate mldings are razr sharp. Althugh they prbably wuld nt cause a serius injury, why risk painful cuts when a gd pair f wrk glves can prtect yur hands? We als recmmend using ear prtectin - ear plugs r ear muffs - whenever yu are perating pwer tls. It can help prevent permanent hearing damage. STORAGE Keep Decrative Edges in packaging tubes until ready t fabricate. Mldings are packaged in a plastic sheath and a cardbard tube. It is best t stre the mldings in this packaging t eliminate warping and pssible damage t the mlding. 3

4 Wilsnart Decrative Edges Tl Kit 1/4 Dad Cutter Clipped Crner Ruter and Template Guide 10 Disk Sander 90, 45, 22-1/2 Miter Gauges 90, 45, 22-1/2 Phenlic Attachment Plates 4

5 Wilsnart Decrative Edge Phenlic Plate Attachments Design fr use with Cascade and Crescent SE Munting styles

6 Wilsnart Decrative Edges Phenlic Plate Attachments Design fr use with Cascade and Crescent SE Munting styles

7 Wilsnart Decrative Edge Phenlic Plate Attachments Design fr use with Cascade and Crescent SE Munting styles

8 Wilsnart Decrative Edge Fabricatin Cut the substrate t the desired size, (tp shuld be 1/8 larger) place the substrate face side up n a flat wrk surface and thrughly brush the substrate surface clean. FIGURE 1 STEP 1 Place a 90 miter gauge n the frnt f the cuntertp. Place straight edge against miter gauge and align alng the edge f the cuntertp. Hld the miter gauge firm against cunter, check the straight edge t see if it is flush with the cuntertp edge. If the straight edge is flush with yur cuntertp, the cuntertp is square. If nt, back the straight edge up apprximately 1/8 keeping it square against the miter gauge. (FIG. 1) Clamp the straight edge int place. NOTE: If cuntertp is square, withut inside crners, use the Decrative Edge straight cut planner t plane the edge. (Prceed t Step 3). FIGURE 2 STEP 2 Clamp straight edge t the edge that is t receive mlding. Use a ruter with 2 flute cutter and template guide. Wrking left t right, trim ff apprximately 1/16 frm the cuntertp. D the same fr all edges t receive bevel mlding. (FIG. 2) NOTE: Exercise care t assure a chip free machined edge surface. STEP 3 When using SE-style mldings, use the 1/4 Dad Cutter t machine the dad int the substrate. Always rut in a left t right directin, using a smth cnsistent mtin. (FIG. 3) FIGURE 3 NOTE: When using FE-style mlding, it is recmmended t attach build-up supprt strips t the cuntertp prir t dry-fitting mldings. Build-up strips must be flush with edge f cuntertp. Supprt strips are required when using Crescent mldings. STEP 4 Measure the substrate edges and rugh cut the mlding pieces (wrking in a right t left directin). Leave at least three quarters f an inch (3/4 ) f excess n bth ends f the mlding piece. (FIG. 4) FIGURE 4 8

9 STEP 5 When sanding the mitered edges fr Bevel SE-style mldings, start with the mlding laminate side t the miter gauge with the bevel side up, sand the edge t a miter. Alternate the mlding - bevel up/bevel dwn - fr each miter. Always keep the laminate side t the miter gauge.(fig. 5) Wilsnart Decrative Edges Fabricatin NOTE: Inside crners will cause yu t change the directin f the miter gauge n the disk sander. When sanding the mitered edges fr Cascade SE and Crescent SE style mldings, use the mdified miter gages with phenlic plate attachments (FIG. 6). Insert the 1/4 wd tngue f the SE mlding int the dad slt in the phenlic plate attachment. Alternate the tngue up and dwn in the dad slt fr each miter. Always keep the wd side t the miter gauge and phenlic plate (FIG.7) NOTE: Inside crners will cause yu t change the directin f the miter gauge n the disk sander. When sanding the mitered edges n the Bevel FE, Cascade FE and Crescent FE mldings use standard r mdified miter gauges. Keep wd side f the mlding t the miter gauge. Miter gauge n the left t create inside crners and miter gauge n right t create utside crners. Always keep the wd side t the miter gauge/phenlic plate. STEP 6 Wrking right t left dry fit each mlding. Use a white rubber mallet t dry fit SE-style mldings int the dad grve arund the tp f cuntertp. Fr FE-style mlding, use filament tape. FIGURE 5 FIGURE 6 FIGURE 7 STEP 7 Use a sharp pencil t mark the miter psitin f yur mlding pieces. Repeat this step fr each additinal piece. (FIG. 8) STEP 8 Sand yur miters t the precise length yu have marked, and brush all the mlding pieces clean. Always use disc sander, nt a miter saw, t finish all miters. 9 FIGURE 8

10 Wilsnart Decrative Edges Fabricatin CAUTION: After dry fitting and scribing the mldings, carefully remve them and prepare mldings and cuntertp fr adhesin. STEP 9 Apply a bead f Wilsnart Type II adhesive t the tp and bttm inside crner f the SE-style mlding tngue. (FIG. 9 & 10) FIGURE 9 NOTE: Excess squeeze-ut prvides n additinal benefit and cmplicates clean up. STEP 10 Smth ut the bead f Wilsnart Type II n the tp f the tngue with the tip f yur finger. (FIG.11) FIGURE 10 When adhering FE-style mlding apply a 1/4 bead f Wilsnart Type II adhesive and spread adhesive t the entire wd area f the FE mlding. CAUTION: Use care nt t slide yur finger ver the laminate edge f the mlding. It is sharp and will cut yur skin. NOTE: Yu d nt want any glue squeeze-ut n the tp f the mlding. Glue squeeze ut n tp f the bevel may cause separatin frm the cuntertp. If squeeze ut ccurs wipe ff with a damp clth immediately. FIGURE 11 STEP 11 Apply vertical strips f filament tape ver the length f the mlding every 3-4 t hld the mlding in place until the adhesive dries. (FIG. 12) NOTE: Apply the tape t the face f the mlding using upward pressure. FIGURE 12 10

11 STEP 12 Put a small amunt f WIlsnart Type II adhesive n the trailing end f each mlding piece befre installing it. Then, use filament tape t hld the crners in place while the adhesive dries (apprximately 30 min.) (FIG. 13) Wilsnart Decrative Edges Fabricatin NOTE: Glue squeeze ut n tp f the bevel may cause separatin frm the cuntertp. If squeeze ut ccurs wipe ff with a damp clth immediately. FIGURE 13 STEP 13 Recmmended - turn the tp ver (face dwn) and add build-up/build-dwn strips t all exterir edges f the substrate that have received SE-style mlding strip. (FIG. 14) When using FE-style mldings, it is recmmended t attach build-up supprt strips t the cuntertp prir t dry-fitting mldings. Buildup strips must be flush with edge f cuntertp. FIGURE 14 NOTE: When using FE-style mlding, it is recmmended t attach build-up supprt strips t the cuntertp prir t dry-fitting mldings. Buildup strips must be flush with edge f cuntertp. Supprt strips are required when using Crescent mldings. When adding the build-up/build-dwn strips, it is recmmended that Wilsnart Type II and staples be used, t attach the strips. CAUTION: Exercise care when selecting the length f the staple t be used when attaching build-up/build-dwn strips. Inapprpriate length staple(s) will cause damage t the tp surface. 11

12 Wilsnart Decrative Edges Clipped Crners Typically, the design fr a custm built Decrative Edge Cuntertp will cntain at least ne 90 utside crner. Althugh these crners are csmetically pleasing t the eye, a custmer may request that yu sften the 90 angle by clipping the crner(s). The fllwing is an efficient and accurate methd fr clipping 90 utside crners n a pre-laminated tp. STEP 1 On pre-laminated substrate that cntains a 90 utside crner. Use the Decrative Edge Straight Cut Planer t machine bth substrate edges t which mldings will be fitted. FIGURE 1 STEP 2 Invert 45 miter gauge and place nt the cuntertp. Align the end f the gauge with the edge f cuntertp (FIG. 1). Using a pencil, draw a line nt the cuntertp alng the frnt edge f the miter gauge. This will establish the crrect 45 at which t machine the clipped crner (FIG. 2). STEP 3 Align straight edge n line and clamp. NOTE: The 45 miter gauge accurately psitins the pencil line s that the clip crner ruter can be used t machine the substrate. FIGURE 2 CAUTION! This prcedure is based upn the cuntertp verhanging the cabinet face by 1-inch n bth sides f the crner. Additinally, the clip crner ruter is fitted with a special 6-1/2 diameter base plate. If yu chse t use a ruter having a base diameter ther than 6-1/2, it is necessary t adjust the psitin f the traced line. STEP 4 Yu are nw ready t apply SE r FE-style mldings. Fllw steps in Fabricatin Techniques fr the Decrative Edge f yur chice. 12

13 Wilsnart Decrative Edges Clipped Crners - Building a Template STEP 1 Cnstruct a Template (FIG. 1) This can easily be accmplished by cutting 2-1/2 wide strips frm 3/4 particle bard that has been laminated n bth sides. After cutting the strips t the apprpriate lengths, align the lngest strip against the drawn line (n the laminated substrate) and secure in place with standard laminate clamps. Use 1-1/4 Phillips head drywall screws t cmplete the Template assembly. STEP 2 Psitin the Template nt yur cuntertp substrate and secure in place using standard laminate clamps at the lcatins. (FIG. 2) NOTE: Machining thrugh 3/4 cuntertp (with a 1/2 bit) can prduce a pr quality cut n the edge surfaces f the substrate. It is always best t first make a rugh cut and then a secnd finishing cut. This prcedure can mre easily be accmplished by attaching (with filament tape) a strip f laminate t the frnt side f the Template. (FIG. 3) STEP 3 Make the first (rugh cut) with the laminate between the ruter base and the Template. (FIG. 4) Then, flip-up the strip f laminate (using the tape as the hinge) and make the secnd (finishing) cut. The result will be a finish cut that is equal t ne prduced by the Straight Cut Planer. Cmplete the prcedure by remving the Template frm yur cuntertp. Yur clipped crner is nw ready fr the machining f the dad grve. Upn cmpletin f that step, installatin f the Decrative Edge mldings arund the clipped crner can be easily accmplished by mitering the mldings with the 22-1/2 miter gauge. FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 13

14 Wilsnart Decrative Edges Outside Radius Crners (Wd Mldings) The Radius Crner Template prvides an accurate methd fr the machining f exact 2, 4, and 6 utside radius crners. The Radius Crner Template is a useful and necessary tl when fabricating with Decrative Edge Slid Wd Mldings. Cntact yur Wilsnart distributr fr rdering and pricing infrmatin. The fllwing steps will help assist yu in fabricating Decrative Edge radius mldings. STEP 1 Straight cut plane the edges f the cuntertp. NOTE: Be sure that cuntertp is square and flat. STEP 2 Psitin the Radius Crner Template nt the cuntertp and draw line n cuntertp. (FIG. 1) FIGURE 1 STEP 3 Remve the template and cut within 1/8 f the line with jig saw. STEP 4 Psitin and clamp the Radius Crner Template nt the cuntertp. (FIG. 1) NOTE: Make sure the template is flush with edges f cuntertp. If using bttm bearing bit, clamp template t bttm f cuntertp then fllw steps. STEP 5 Set the depth f the 1/2 tp bearing guided, tw flute cutter. (FIG. 2) NOTE: Make sure bearing is psitined n template. STEP 6 Machine the prfile frm left t right. STEP 7 Remve template FIGURE 2 STEP 8 Yu are nw ready t cut dad. Refer t Adjustment Prcedures Fr The 1/4 Dad Cutter in the Tl Setup sectin f this manual. 14

15 The Decrative Edge prduct line utilizes a system apprach fr the fabricatin f custm designed tps. The system prvides precisin high pressure decrative mldings and clse tlerance slid wd mldings in varius styles and designs, alng with unique fabricatin equipment, specifically designed t wrk within the mlding tlerances. All f these are imprtant elements that make the system wrk. Fr the past five years the inside crner has been a majr cncern in fabricating Wilsnart Decrative Edges. We have nw designed a simple phenlic template that takes the guess wrk ut f inside crners. The inside crner phenlic templates are available thrugh AMPS Edge in 45 and 90 angles (AMPS Interlcking Straight Edge System, , ampsedge@verizn.net). The phenlic templates can assure quality fabricatin by fllwing these simple fabricatin steps. STEP 1 Oversize cuntertp by 1/8. Psitin inside crner template 1/8 frm edge f cuntertp. NOTE: Make sure yu are 1/8 frm the edge f the cunter n bth sides f template. (FIG. 1) Wilsnart Decrative Edges Inside Crners STEP 2 Clamp template int place. Using a mechanical pencil trace a line n the inside f the template. (FIG. 1) FIGURE 1 NOTE: Duble check yur measurements t assure accuracy. STEP 3 Use a ruter with a straight duble flute bit and template guide t rut inside crner. (FIG. 2) Remve inside crner template and feel edge fr smthness. NOTE: Prter Cable, Template Guide #42046 (5/8 ) FIGURE 2 15

16 Wilsnart Decrative Edges Inside Crners STEP 4 Take straight edge and align it with pencil mark n cuntertp. (FIG. 3) NOTE: Make sure yu are 1/8 away frm edge at end f cunter. FIGURE 3 STEP 5 Clamp straight edge int place. (FIG. 3) Rut edge with Ruter, duble flute bit and template guide. (FIG. 4) STEP 6 Remve template and repeat steps 4 & 5. STEP 7 If using SE-style mldings, yu are nw ready fr yur Dad cutter. FIGURE 4 NOTE: The template guide causes a 1/16 separatin between the bit and the guide. The 1/8 distance that yu psitin yur straight edge and inside crner template frm the edge f the cunter will allw yu t trim 1/16 away frm the substrate. This methd will eliminate the use f the straight cut planer. STEP 8 Cut and fit all mldings. 16

17 The AMPS Interlcking Straight Edge System is a cmplete straight edge system that is designed t wrk with nly tw clamps n matter hw lng the run. Inside crners are n lnger the time cnsuming hassle they have been in the past. The AMPS system eliminates all f the guess-wrk and time cnsuming fabricatin steps currently invlved in inside crner fabricatin. By placing the AMPS system nt the wrk surface and applying ne clamp at each end f the system, planing r ruting can be dne in ne cntinuus step. The system includes: 1 31 Phenlic Straight Edge 1 48 Phenlic Straight Edge 1 96 Phenlic Straight Edge 1 Jining Plate (used t jin tw female ends) 1 90 Inside Crner Template 1 45 Inside Crner Template Other sizes available. Call AMPS Edge ( , ampsedge@verizn.net) fr prices and availability. Fllw these steps t use the AMPS straight edge system with Decrative Edge Mldings. STEP 1 Set AMPS system nt square prelaminated cuntertp fr assembly. (Fllw straight edge instructins fr prper assembly) STEP 2 Align system 1/8 frm the edge f cuntertp. (FIG. 1) Wilsnart Decrative Edges AMPS Interlcking Template STEP 3 Place ne clamp at each end f cuntertp t hld the system int place. (FIG. 1) FIGURE 1 STEP 4 Duble check measurements t assure accuracy. STEP 5 Place ruter (with tw fluted cutter and template guide Prter Cable #42046) nt straight edge and rut the frnt edge f the cuntertp. (Always rut frm left t right) (FIG. 2) STEP 6 Remve clamps and straight edge system. FIGURE 2 STEP 7 Yu are nw ready fr the dad cut. 17

18 Decrative Edge Prfiles Laminate (FE, SE) When rdering, specify prfile type and pattern/finish fr each face. Bevel Edge Style - FE, SE Face A. 1 9 /16" B A 1 9 /16" B A Pattern/Finish Face B. Pattern/Finish Beveled Lengths: Prfile 144" (FE) Lengths: Beveled 144" Prfile (SE) Prfile (FE) Prfile (SE) Available Patterns/Finishes: All Wilsnart Laminate 1/4 1/4 1 9/16 1 9/16 3/8 Cascade Prfile (FE) 3/8 Cascade Prfile (SE) 1/4 1/4 1 9/16 1 9/16 3/8 Crescent Prfile (FE) 3/8 Crescent Prfile (SE) 18

19 Decrative Edge Prfiles Slid Wd (HT, KT) Wd Style - HT-1, HT-11, KT /16" 1 9 /16" 1 1 /16" 1 1 /16" 1 1 /16" 5 /8" 5 /8" 25 /32" Lengths: 144" Lengths: 144" Lengths: 144" Prfile (HT-1) 3/8" Bevel Tp Prfile (HT-11) Square Prfile (KT-1) 1 9/16" Half Rund Available Species: Red Oak, Hard Maple* Available Species*: Red Oak Hard Maple Als available withut tngues: HN1RO Bevel (Red Oak) HN11RO Square (Red Oak) KN1HM Half Rund (Hard Maple) Wd (Runded Crner) Style - RHT-1, RHT-11, RKT /16" 5 /8" 1 1 /16" 1 9 /16" 5 /8" 1 1 /16" 1 9 /16" 25 /32" 1 1 /16" 2 Radius 4 Radius 6 Radius Lengths: 2" radii Lengths: 2" radii Lengths: 2, 4, and 6" radii Prfile (RHT-1) Runded Prfile (RHT-11) Runded Prfile (RKT-1) Runded Crner 3/8" Bevel Tp Crner 3/8" Square Tp Crner 1 9/16" Half Rund Available Species*: Red Oak Hard Maple * Special rder species: Cherry, White Oak, White Birch and Black Ash. Minimum rder quantity: 10 each 12 length mlding per specie and style. Lead time: 4 t 6 weeks. Call yur Wilsnart distributr fr a price qutatin. 19