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I've made new tops for my live box out of corian. I need to attach a piano hinge and was wondering the best way to do this. From what I've read, you cannot tap or screw corian because it will not hold and/or crack.
Can you drill out a hole (x2 the diameter of the screw), epoxy a wooden dowel into the hole and then drill and screw into the dowel without cracking the corian?
There are a billion comments that come to mind with your subject line, but this is a family site!!!!
Have you thought of drilling THRU the corrian, or is it possible for your design? You can back it up with a piece of flat metal with a piece of rubber underneath to stop it from cracking, kind of how they use rubber washers for car windows.... Countersink the metal and use flat head screws.....
... and if you can, you could possibly forget the corrian and use Starboard .. .you can tap that really easily...
I've tapped hundreds of holes in Corian with no problem at all. You'll want to use the same tap drill you'd use for aluminum and it is best to use coarse threads. WD-40 works great as a tapping fluid for it.
Who's Corian? Oh, yea..that stuff. Kern has the answer. Corian is an acrylic product, and is relatively soft. It's worked with woodworking tools. Play with some sample pieces first.
Kerno means tapping threads, not running a self tapping screw.
I have repaired dozens of tops in boats due to improper installation, a big no-no is self tapping threads, the other is the top not being fully
supported by a backer.
The best way is to install a threaded insert....for the size you need but I wouldn't do it with all those holes required for a piano hinge...the spacing between those holes will eventually cause stress cracks between the inserts...It's 100% acrylic and very brittle....
I cant see comparing starboard to corian, nasty plastic to a fine surface like corian? Your not supposed to be putting screws into starboard either and thru-bolting a piano hinge is nutso.
the last custom corian top we made had part of it that hinged, remember that if you bullnose the corian your wood backer will be underneath it, where it hinges you can easily use a piano hinge because it will be screwing into wood not the corian.
Just as a tip- make it all one piece, THEN cut it where you want it to hinge, the thickness of the blade should be just about right for your hinge to fit.
"Your not supposed to be putting screws into starboard either " - Since when. That is the only effective way to join Starboard - there is no glue that will hold it.
I cant see comparing starboard to corian, nasty plastic to a fine surface like corian? Your not supposed to be putting screws into starboard either and thru-bolting a piano hinge is nutso.
Second that! Some "advise" here is nutso. Starboard is the last thing i would want exposed in a conspicuous spot like ahatch/well cover.
Ask a corian counter shop how they attach undermount sinks.
That is the only effective way to join Starboard - there is no glue that will hold it.
Good news: If you ever do need to glue it, 3M does make a 2 part adhesive specifically for bonding Starboard. It takes an applicator gun and the setup, with glue cartridges, will cost you about $100.00. When you are done, the Starboard will be very well glued. The glue is slightly yellow in color, so it cannot be used to hide a joint unless you make the edges fit perfectly and then put a gluing groove in the joint faces..
"Your not supposed to be putting screws into starboard either " - Since when. That is the only effective way to join Starboard - there is no glue that will hold it.
you should be bolting it together, I would not trust a screwed in hinge if it was a larger door. For a smaller door it would not be as critical.
• Never install mechanical fasteners (screws, nails, etc.) into Corian®. Brass inserts are the only approved fastener.
From the Fabrication Manual, pages 161, 162:
If using surface-mounted accessories, do not screw directly into Corian®. Screws must attach into the stud or supporting block.
1. Drill through Corian®. Holes should be 1/8” (3 mm) larger than diameter of accessory screw.
2. Insert silicone in hole before inserting screw. Do not overtighten.
From the Fabrication Manual, pages 183, 184:
13. Fixing Corian® Countertops to Base/Cabinet Units
There are several ways to secure countertop to cabinets. The two most popular ways are silicone adhesive or screws. If Corian® is set directly onto perimeter support, use small dabs of silicone such as GE 1200 Series sealant, no closer than 12” (305 mm). If wood support is attached to underside of countertop with silicone, screws can be used as follows:
Drill holes in the back and front cabinet rail, using a high speed drill about 1/8” (3 mm) larger than the screw to be used to fix the countertop down to the base/cabinet units.
Select screws that will not pass through the supports, and screw into the support rails, taking care not to overtighten the screw.
Screwing directly into Corian® is not allowed and cause the Corian® to crack.
From the Squirrel System information flyer:
Installation Method:
- Set out and prepare Corian(r) to be "Squirreled".
- Machine/Route a 20 mm diameter hole that is 8 mm deep.
- Assemble Squirrel(tm) and DRY FIT it. It should Finish 0.5 mm - 1mm proud of the surface.
- Clean the hole with de-natures alcohol ready for the Corian(r) adhesive.
- Apply the Corian(r) Adhesive as normal, ensuring is pumped into the hole for the complete surface contact with the Squirrel(tm) and the nut.
- Press the Squirrel(tm) into the hole: no clamps required.
- Rotate Squirrel(tm) to ensure even coverage of adhesive.
- Glued in Squirrel(tm) showing the adhesive spewed over onto the surrounding surface.
- Sand off the excess adhesive once it has cured (40 mins) making sure each Squirrel (tm) is flush.(P80 abrasive through to fine).
Using Squirrel® technology with specially developed Blum new hinges, Corian® can now be used to create kitchen and bathroom cabinet doors or doors for many other new applications.
The combination of the Squirrel® technology and specially developed Blum hinges, now means that Corian® can be used without being bonded to a substrate, and as a stand-alone material for kitchen and bathroom cabinet doors.
The system consists of 2 Corian® Squirrels and a Blum hinge, which completes the installation package.
Southatlantic is right. Don't use any hardware that you would not use on a glass panel. You might want to consider using Lexan or a similar polycarbonate. It will never crack, split or break and is just as easy to fabricate as Corian.
undermount sink are usually epoxied in place. typically the way to attach corian is it should have a plywood or mdf backing. this can be screwed into. you can drill though corian but it's a good idea to have sharp bits and wd-40 or silicone spray. It can crack around the stress point so be sure to support it somehow
__________________ Chatham, MA
22' Seawolf
20' Ski Barge
14' O'day
You can definately drill & tap Corian... I've done it many times. The trick is to tap it as deep as possible. I have hinged corian in my shop. Put a little epoxy or even some 5200 on the screws before you sink them... lubes them up then locks them in place. DO NOT OVERTIGHTEN! If you're putting a piano hinge on the edge, you might want to put some epoxy between the hinge and the Corian as somebody previously mentioned.
Almost forgot... pre-drill with a smaller bit, then run a countersink bit in to flare the hole wider than the tap bit. This keeps the edges from popping out and relieves the stres caused by the sharp corners of the drilled hole. Corian does not like sharp edges.
You can definately drill & tap Corian... I've done it many times. The trick is to tap it as deep as possible. I have hinged corian in my shop.
But there's going to be a lot more vibration on a boat than on a typical home or commercial installation. While it may be fine when constructed, I would worry about long term results.
screwing corian 
