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Old 04-06-2016, 08:16 AM   #1
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2016 FC: Sharp Edges on Formica Counters

Hi, we bought a 2016 27' FC FB in December. Love our AS. We are on our inaugural trip out west.

Many if not most of the formica countertop edges were left with a very sharp 90 deg edge from the factory. In looking closely at the edge, the finish strip glued to the edge was left straight up, and at a very sharp angle / edge to it, where it joins the horizontal part of the counter.

I've found that, as a new AS owner, I've banged my hands into these edges several times, enough that it is painful.

Is there a preferred way to relieve this sharp edge?

I was just going to get some fine sand paper and gently rub down the edge to give it a slight rounded off profile. Another thought was to use an emery board and gently file the edge at a 45 deg angle to do the same thing. Of course, I don't want to incite Panic from my wife when I come into the trailer with tools in hand to make a modification to her beautiful interior, so I am asking the experts.

Thanks!

Rich
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Old 04-06-2016, 08:38 AM   #2
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I have the same problem. The dinette table bugs me so much I am thinking of changing it out!
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Old 04-06-2016, 10:41 AM   #3
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Typical...
A wood block with "crocus cloth" (mechanics emery cloth) which you purchase on a spool from NAPA or other high end Auto Parts store will give a smooth sanded area.. Very LOW pressure. You can "round off" the edge or sand carefully at desired angle.. Remember... Go along the edge, not at a sharp angle so you do not chip the edge.

You can also use a router with a bearing to keep it true on the edge.. That is what professionals use. They then "feather by hand sanding" in the tight spots.

If uncomfortable with this, get dealer to fix. It is a safety issue. Unfortunately not the only one on the new Airstreams I have seen.
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Old 04-06-2016, 11:37 AM   #4
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I would try a fine emery board at a 45 degree angle to the horizontal (or vertical) in an inconspicuous place until you get the result you want. I would not use any power tools to do this.
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Old 04-06-2016, 11:49 AM   #5
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Lland088, there is nothing wrong with your approach. Get one of those fingernail boards with four sections of light to polish finish grit and have at it. It does not take much to round over the sharp edge so it doesn't cut into skin, just avoid the coarser grits. All the methods mentioned above work: specialty tools are overkill.
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Old 04-07-2016, 11:45 AM   #6
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Boy am I glad to see this thread! I cut myself on the sharp edge of the countertop above the refrigerator. I was pondering how to sand it down without chipping the edge....I will definitely follow this thread.
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Old 04-07-2016, 11:53 AM   #7
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On my first trip out with the brand new 25' FC, FB, THE EDGES OF the dinette seats carved gouges into my leg behind the knee.
So I took photos of the 'damage" and showed them to the dealer in London. The guy rounded the edges somehow and it was good.
No more leg damage.😊
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Old 04-07-2016, 01:58 PM   #8
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Formica is a very hard material. When I apply it to countertops in my workshop, I use a carbide router bit to round over the edge. For spots that I can't get to with a router, I use a medium metal file and it works very well. I like the rigid file as it provides control as to exactly where I want to apply the pressure. An emery board may work but be prepared for possibly slow removal of material if doing a lengthy edge. For sandpaper, I suggest wrapping the paper around something rigid such as a small piece of wood.

I also find it works better to move the tool lengthwise along the sharp edge as you remove the material. (don't sand/file vertically up and down in one single spot)

Good luck.
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Old 04-07-2016, 07:32 PM   #9
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when I made my counter top I did the final edge touch ups with a rigid file at 45 .... worked great .......but at what you paid I would scream blue murder to the dealer!! Doesn't sound like your the only one!
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Old 04-07-2016, 08:31 PM   #10
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If you need a color matched filler, here it is: http://www.kampelent.com/seamfil.php
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Old 04-07-2016, 09:57 PM   #11
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Quote:
Originally Posted by ddbisho View Post
I use a medium metal file and it works very well. I like the rigid file as it provides control as to exactly where I want to apply the pressure.
I also find it works better to move the tool lengthwise along the sharp edge as you remove the material. (don't sand/file vertically up and down in one single spot)
When our 2002 was new, the edge banding on all cabinets and doors had edges sharp enough to cut our hands. Having had experience with Formica, I did just as ddbisho suggests and used a file (a fine-cut mill bastard file) and rounded every edge. The result? A luxurious feel for all doors and edges.

If you use a file, most effective is filing lengthwise from the surface slightly towards the glue line and at an angle that give you a bit of a chamfered cut. Then use the file to round the resulting edge. No sandpaper is necessary

Tim
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Old 04-07-2016, 10:06 PM   #12
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I think I touched ours lightly with a file moving carefully and slowly along the edge, file almost flat to the top and then side surface. I don't think you really want to round it off much, just enough to take a tiny edge of the top then side laminate. If you expose the plywood underneath it can absorb water, possibly expand. Take it easy, you can remove too much material quickly.
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Old 04-08-2016, 12:14 AM   #13
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Sharp edges on formica counters.

Hi, I didn't have this problem with my trailer, but I did have it with my new house. I cut my arm open a few times before I finally fixed it. I used a metal finger nail file to smooth out the sharp corners.
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Old 04-12-2016, 01:51 PM   #14
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Problem solved.

Bought a set of coarse, medium and fine emery paper at Lowe's. I wrapped the fine around a soap container to use as a block, and gently rubbed the sharp edges down. Ran a damp cloth over, edge is much smoother now.

Just a couple strokes is all it took.

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