I am setting up a new 5 x 10 PRS Alpha and could use some advice on my table. I have two sheets of Formica 60 x 144 Phenolic that I would like to use. My questions are:
1. What should I use to glue them together, or should I ?
2. What bits, feed and speed to cut plenum ?
3. Any pros & cons I should know about ?
Thanks in advance !
You can glue phenolic to phenolic with contact cement, epoxy, or Duco (if you want to buy a case of little tubes!).
This is a very dense material in thickness and should be milled with a bit suited to plastic, like an o-flute, and not too fast. Upcut style.
I would likely take my time and do it around 2ips with a 3/8 or 1/2" bit spinning around 8-10k. It would vary depending on 1 flute, 2 flute.
Dust from it is heck, heavy stuff, very stable. Excellent for base and plenum. Not too many SBers use it due to cost.
I would do absolutely everything I could to ensure my rig is as true and level before skinning the plenum flat pre spoilboard.
And that gets to the possible con. You need to ensure your spoilboard properly adheres to the plenum. I wouldn't trust yellow glue for that.
So you would likely need to use epoxy again.