Tips for enlarging cooktop opening in corian countertop

Wow. Sounds like a tough problem to me. I’ll wish you luck with it. There aren’t too many visitors to this site but the few pros who log in a few times a week are really good and incredibly helpful. Hang in there. Knowing these guys, I bet you will have the right solution in no time.

Welcome to home refurbers!!

-- Working on my home for 2 years and counting.

If taking the counter off and cutting it from the bottom side is out of the question then I would suggest using an oscillating cutter like the Fein multimaster or sonicrafter, there are many brands out there now. Use a metal/wood blade or a metal blade. Corian is essentially hard plastic, so it will burn a little bit and not produce a perfect cut with the oscillator. You can sand the cut flat and smooth if you need a good seam. If the cut has to look perfect I would lift the counter up and cut from the underside. Chances are it’s only spots of silicone holding down the counter top.

Good luck.

-- I found the board stretcher... finally!

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Thanks for the suggestions. I ended up buying a smaller router that was able to get where I needed it to get and that solved the problem. The cut looks almost perfect, but the cooktop hides the cutout anyway so there’s no way you can tell that the cooktop was replaced (except for the fact that the cooktop is 36” and the hood is 30”, but most folks won’t notice that).

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