How do I fix a corian countertop?

by Valerie

My corian countertop has a chip. How can I fix it myself on a budget? Don’t want to pay hundreds of dollars for a professional. I just need to find the right product to fill the hole. Thanks

  3 answers
  • Mogie Mogie on Nov 18, 2018

    First, you need to get the matching epoxy for your solid surface material. Look at this website and buy your matching color. Getting the right adhesive (epoxy) is very important. The epoxy comes in a dual caulking gun cartridge. Don't bother buying the special dispenser gun, just modify an old caulking gun to compress both cartridge cylinders at once. It's not hard to do, and you only need a small amount of this epoxy to fix the crack.

    You also need a small sample piece of the exact material that your counter top is made from. We had a small cutting board size piece that came with the countertop when it was first installed. If you do't have this buy a small sample from the same website that sells the adhesive. You only need a small piece. Even scraps of the matching color will work for this repair.

    You must first stabilize the countertop so the crack does not flex and so it can't grow. To do this I recommend using a ceramic tile, epoxied to the underside of the countertop. The tile or tiles should overlap the entire length of the crack. Use a good high strength epoxy to glue the tile to the underside of the countertop. My crack was over where the dishwasher is, so I had to remove the dish washer to gain access to the crack underside. I used some stools and my car jack to hold the stabilizing tile up against the Corian while the epoxy dried. Getting the top stabilized is important, and the thermal coefficient of expansion of tile is much less that Corian, so it provides a good stable backing for the damaged area.

    The tools you will need include a Dremel with thin grinding wheel, and Black & Decker Mouse sander with 80 grit, 180 grit, 240 grit, and abrasive pad. You also need a good band saw or table saw to slice a very thin sliver from the Corain sample (the sample cutting board, in my case).

    Once you have cut long enough slivers of Corain, use the sander to put a knife edge on the length of one edge. You will find that the sliver of Corian is very flexible and can be bent to match the crack shape. If the crack has sharp turns just crack the sliver into small lengths to match the crack pattern.

    Now use the Dremel tool to grind open a very thin slot along the crack length. Then clean out the slot and test place the slivers into the crack. They don't need to go all the way down into the crack, the sliver is just there to provide color match, not structural strength. The tile epoxied underneath provides all the structural strength.

    Then fill the crack slot with the color matched epoxy and wedge the Corian slivers into the slot. They will probably only go in about 1/3 of the thickness, but that is plenty of depth to work. The epoxy dries quickly, so don't dilly-dally. When the epoxy is dry, about 1 hour, use your Dremel wheel to carefully grind off most of the Corian sliver sticking up from the slot.

    Then sand with 80 grit until the sliver is even with the countertop. You will start to see the crack disappear. Move to 180 grit, then 240 grit, then finally the abrasive pad, and like magic the crack will completely disappear.

    • William William on Nov 18, 2018

      Too complicated for a DIY. Simpler solutions are available. Two part epoxy or Bondo.

  • William William on Nov 18, 2018

    You can use a two part epoxy to fill the chip. Another option is to fill with Bondo, auto body filler. Sand smooth. Use craft paint or Sharpies to color.