Formica

[Graham_Wright]

I brought the jig saw home from the boat to try as a solution. I now think the angle grinder would be a better solution.

Guess where the angle grinder is.

I'll bring home the die grinder as well.

 

[Graham_Wright]

I have one of these that I fit a 1mm abrasive cutting disk in to.

It gives me better control than by battery angle grinder.

But no so good for corners?

 

[rogerthebodger]

But no so good for corners?

Great for straight cuts. The trick is to only have the cutting disk to only just over the material thickness

But for curved corners I would use a dremel or hole saw depending on the radius combined with

Another way is with a router and a 3mm bit.
Straight cuts using a straight edge of curves with a trammel bar attachment.

You could also cut freehand

 

[Graham_Wright]

I have a vintage Goscut (as shown in post 8). It has two alternative cutters, one for straight cuts and a second for more intricate curves. If you'd like to borrow it, PM me.

Thanks for the offer Pete.

The die grinder is working fine although it is very tedious. With the material so expensive, time is not so important.

I might try the angle grinder for the straight cuts.

 

[Graham_Wright]

Report back. The angle grinder with a 1mm (thick not diameter as I first wondered!) worked a treat. No chatter was the big step forward. The die grinder with a 1mm diameter slot drill coped with the curves. Now to transport it to the boat without damage.

 

[Solent sailer]

i have always cut over size and finished with a router

 

[Graham_Wright]

i have always cut over size and finished with a router

In my case, the formica is for the heads bulkhead. Not easy to use a router up in the air! There is insufficient room on board to find sufficient support while routing. I had a precise template to work from so fingers crossed.