How to cut and drill Think Solid benchtops?

[Fumi]

I’m currently renovating my kitchen as a DIY project. I ordered custom Think Solid™ 38mm bench tops from Bunnings. I have some questions about drilling and making cut-outs in the bench tops.
The instructions say: “Router (1800–2300 watts / 2.5–3hp) (used for cut-outs in Think Solid™ Custom bench tops),” but the tools I have are only a trim router (400W), a jigsaw, a drill, an impact driver, and a circular saw.

I’d like to drill the tap hole using a hole saw attached to the impact driver, and for the sink and induction cooktop cut-outs, I’m thinking of drilling holes in the four corners with a hole saw and then cutting between them with a jigsaw. Is this method feasible?
If it is, what type of hole saw and jigsaw blades should I buy? All my tools are RYOBI.
I’d also appreciate any advice or precautions I should be aware of.

[MitchellMc · Accepted solution]

Welcome to the Bunnings Workshop community @Fumi. It's wonderful to have you join us, and many thanks for your question about benchtops.

There are two options for cutouts on the Think Solid benchtops. The first is a track circular saw, or you can use a router. Your router is not powerful enough to push through a 38mm benchtop. You would have to push it hard to cut, and the RPM would drop, leading to burning the surface and the core. A jigsaw would also struggle on that thickness and will also chip the surface. Think benchtops do not recommend the use of a jigsaw.

Now, you could use your circular saw if you set up guides to run it along. However, a battery-powered saw might require several battery charges as the 38mm benchtop will drain them quickly, and you must use a blade suitable for cutting non-ferrous metal. I'm not entirely sure why that is, but it is the advice I've been given from Think benchtops. It likely has to do with the carbide tooth tips.

Here's another installation guide, which talks about using a saw and a holesaw for the corners. 

Precaution-wise, I would ensure any guides/fences you create are firmly clamped down so they don't drift whilst cutting. Also, ensure the benchtop is fully supported by your cabinetry before making the cuts. On cabinetry, ensure your cut path is free from it beneath and adjust as necessary. You don't want to start cutting the sink out and realise you are cutting through the top of the cabinet carcass.

Please let me know if you have any questions.

Mitchell