Dear All,

I would like to laminate 1/16" lead sheet to 3/4" MDF. No.. I am not in the funeral business, but a 30 year life-span for the laminate would do just fine.

I'm thinking of de-greasing the lead sheet, lightly abrading it, and using phenol-formaldehyde wood glue, putting the assembly in a vacuum bag ( about 0.7 bar vacuum), until the glue does its stuff.

After that, it would be really good to be able to rout rebates through the lead and into the MDF.

The rebates would be attempted with a hand-held router. Given that the subsequent joints will be MDF to MDF, I think it would not be a good idea to use greasy cutting fluids on the lead because the greasy stuff will migrate into the MDF. Yeah, I know lead is going to stick to even the sharpest router bit.

Help me dudes, or tell me it is impossible...

Best Wishes

Martin