My wife dropped a cast iron pot on our glass cooktop, so I just bought a new one and am in the process of replacing old with new. The old one was a 30” model and the new one is 36”. I’ve gone through the process of enlarging the cutout in our Corian countertop by measuring how much larger it needs to be, then I used double sided tape to put edge jointed boards on each side of the opening and used those as a reference to guide a pattern bit in my router. This worked great for all but the portion of the opening that’s within about three inches of the back wall. The problem is the router’s base is hitting the back wall (backsplash area) so I can’t cut back far enough. I don’t have a smaller router (i.e. a trim router) and even if I did I have doubts that a smaller router would have enough power to make the cut. What other options do I have for cutting the area of the countertop that is too close to the wall to get a router in there?
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.
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.
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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