Learn How to Cut Solid Surface Countertops and Unveil Your Hidden Craftsmanship

Secure the solid surface countertop (bottom side up) to a work table, set of sawhorses (with an area of overhang over both sawhorses), or cutting table using clamps. While these countertops aren’t as heavy as marble or granite, they’re still weighty. You’ll need to secure them so they won’t fall while you cut, and you may need a helper or two to lift the countertop. 

You’ll mark the cut lines on the bottom side of the countertop so they’ll be hidden underneath the countertop if any remain after cutting. 

Use the measurements you took in the preparation phase to create guidelines on the underside of the countertop (which should be facing up). Start with the depth measurements (from the front of the countertop to the back). Make marks using a pencil along one side of the countertop. After making several marks, use a carpenter’s square and straightedge to make a straight line between the marks. 

Place the tape measure on the depth guideline you just drew and mark the length at the front or beginning of the countertop and again at the back or end of the depth mark. Use these two marks to draw the depth guideline on the opposite side of the countertop. Use the carpenter’s square and straightedge to draw the guidelines that connect the two short sides of the countertop. These will be your length guidelines. 

After you’ve drawn the lines, check your original measurements and measure your lines again to make sure the depth and length match. Check the orientation with a carpenter’s square. 

You can cut the countertop without a straightedge as a guide, but it provides extra guidance while cutting. You’ll put the base plate of the saw against the straightedge to support it and help get a straight cut.

Line up the straightedge to just beyond one of the guidelines. Clamp it in place so it won’t move while you cut.

Using a circular saw fit with a tungsten triple carbide blade (minimum 40 tooth), line up the cut line of your circular saw with the first guideline. Set the blade depth of the saw to at least 1/8 to 1/4 inch below the height of the solid surface countertop to ensure you cut all the way through the surface. 

Don’t start your cut until the blade is moving at full speed. Then, make a rough cut on the guideline. Stop cutting, and let the saw rest if the friction between the blade and the countertop causes smoke. If you experience kickback, stop and start cutting again.

Repeat the clamping of the straightedge and cutting process on each guideline until you’ve cut the countertop to the necessary dimensions.

You’ll need to refine the rough cut edge left by the circular saw. Use a belt or orbital sander with 220-grit sandpaper to sand the edges of the countertop. You can manually sand the edges, but it can take a lot of time and effort.

Move to 320- and then 400-grit sandpaper to finish the countertop’s edges. The edges should be smooth, which you can check by running your fingers along the edges. You may need to continue sanding with finer and finer sandpaper to get the desired smoothness.

Round and refine the corners of the countertop with a sander. This is an inexpensive counter idea that adds a slightly different style to the countertop. If you like clean, 90-degree angles, you can skip this step.