Solid surface countertops can be easily customized.  Sometimes we overlook the obvious for more fancy ideas.  Grommet holes for electrical cords can be done without expensive equipment or thermoforming ovens.

I have done round grommets in the past, but this was the first request for a custom shape.  Start by cutting the shape into the counter.  It is preferable to route the shape nice and clean.  This step is important for the rabbett.

Next, use a rabbett bit with a bottom bearing to cut a 1/4 x 1/4 rabbet around the entire perimeter.  Cut nice and smooth as possible.

Now that you have this complete, you need to make the insert.  My first round grommets, I just copied the basic shape instead of trying to reinvent the wheel.  Measure the depth of the rabbett and cut a piece down to thickness on the table saw.  Most table saw blades will come up high enough to accommodate the insert.

Position the insert over the hole and mark the bottom side with a pencil.  Cut and sand to line.

The final step is where having a standard plastic grommet helps.  Just trace the small opening of the grommet onto your solid surface insert.  Cut and sand with whatever tools you have available.  Jig saw or band saw works best followed by a small drum sanding drum.  That's it.

If you have a cnc, it makes the process a whole lot easier.  Make the insert .04 smaller and it should fit right in. 

Give this a try on a scrap piece to show potential customers.

About the Author:  Andy Graves is the owner and operator of Olive Mill Manufacturing Inc. in Anaheim California.  Olive Mill specialized in residential and commercial countertop fabrication/installation.  Graves can be reached at olivemill@hotmail.com   Visit his website:  www.olivemill.com