Jonhilgen
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Location: Charleston, SC (USA) Member Since: Dec 2009
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« on: March 20, 2010, 06:39 PM » |
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Hey everyone,
I need to build some cabinets for an outdoor kitchen out of a plastic sheet good. I can't for the life of me remember or find the name of the material (I'm pretty sure it's not Azek), but I think it is mainly used in boat building. The kitchen designer spec'd the carcasses and the doors to be the same white material. I might be able to use Azek for the carcases, but I'm concerned about what the cut edges might look like (minor voids, rough looking). I know that the Atlantis cabinet line uses this material for their outdoor cabinets...
Any ideas?
Your help is greatly appreciated.
Jon
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Peter Halle
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« Reply #1 on: March 20, 2010, 07:08 PM » |
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Does Starboard ring a bell?
Peter
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The tools in my truck were talking the other day. The Dewalts, PC's, Boschs, Makitas were not happy. They also were in the minority. Their complaint: They felt unused and unappreciated since the Festools moved in. I guess the truth hurts.
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WarnerConstCo.
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« Reply #2 on: March 20, 2010, 08:42 PM » |
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If you use azek, sand the cut edges with 180 and paint them.
They now have s4s azek, not sure about the sheets though.
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bruegf
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« Reply #3 on: March 20, 2010, 08:43 PM » |
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Starboard is what I had one one of the boats I owned a few years ago.
Fred
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Fred
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Jonhilgen
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Location: Charleston, SC (USA) Member Since: Dec 2009
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« Reply #4 on: March 21, 2010, 11:39 AM » |
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Does Starboard ring a bell?
Peter
Peter, I think that's the material. And it's only around 500.00 for a 55" x 96" sheet! Yikes...Do you know of anyone on this site that has built cabinets out of this material? This will be the first for me, and I'm wondering what else I might need to machine this material. I'm hoping my 55 with the proper blade will cut it cleanly enough so that I won't have to run a router or joiner on it to clean up the cut edges. But then again, this may be my excuse for buying a Festool router! PS. This is why I love the FOG. |
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Jonhilgen
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Location: Charleston, SC (USA) Member Since: Dec 2009
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« Reply #5 on: March 21, 2010, 11:48 AM » |
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If you use azek, sand the cut edges with 180 and paint them.
They now have s4s azek, not sure about the sheets though.
Cabinets can't be painted, they need to be off-white (I'm pretty sure now the material is Starboard) since the client wants them to be maintenance free. I will hopefully have some time tomorrow to post drawings of the outdoor kitchen so I can lean on the extensive knowledge of others lurking around this site! |
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The more Festools I buy, the more money I earn. The more money I earn, the more Festools I buy. The more...
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Peter Halle
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« Reply #6 on: March 21, 2010, 12:05 PM » |
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Regarding Starboard, here is a place that will do custom fabrication: www.buckwoodcraft.com/custom_woodworking.htmTheir prices are a little better than what you posted - before shipping. Here is another source and a Festool dealer to boot I believe: http://www.jamestowndistributors.com/userportal/search.do?categoryName=Starboard%20Plastic%20Supplies&categoryId=599&refine=1&page=GRID&history=p1jx7jt1%7Ctop_category%7CcategoryName%7EWood%252C%2BFoam%252C%2BStarboard%5Epage%7EGRID%5EcategoryId%7E305Check out the how to fabricate tips on the right of that page for ideas. Designed for the marine industry, you are right that it is expensive. Anything for a boat adds bucks. Peter |
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« Last Edit: March 21, 2010, 12:07 PM by Peter Halle »
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The tools in my truck were talking the other day. The Dewalts, PC's, Boschs, Makitas were not happy. They also were in the minority. Their complaint: They felt unused and unappreciated since the Festools moved in. I guess the truth hurts.
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Corwin
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« Reply #7 on: March 21, 2010, 01:30 PM » |
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I had cabinets made of Starboard on my last boat too. Hated them. Most of the others in the boating group also complained about Starboard. The material is easily marked yet can be tough at times to clean -- been there. But, it is easily machined with woodworking tools and will work for outdoor cabinetry.
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Shirt Size: L
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WarnerConstCo.
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Location: Auburn, In usa Member Since: Apr 2008
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« Reply #8 on: March 21, 2010, 02:12 PM » |
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If you use azek, sand the cut edges with 180 and paint them.
They now have s4s azek, not sure about the sheets though.
Cabinets can't be painted, they need to be off-white (I'm pretty sure now the material is Starboard) since the client wants them to be maintenance free. I will hopefully have some time tomorrow to post drawings of the outdoor kitchen so I can lean on the extensive knowledge of others lurking around this site! I was talking just about the cut edges. Trust me, you can't tell they are painted. The sheets can remain factory white. |
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Peter Halle
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« Reply #9 on: March 22, 2010, 05:08 AM » |
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Here is another link for sheets cheaper than I've seen elsewhere: http://www.modernplastics.com/seaboard8482-premier-sheet-p-1026.htmlPeter |
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The tools in my truck were talking the other day. The Dewalts, PC's, Boschs, Makitas were not happy. They also were in the minority. Their complaint: They felt unused and unappreciated since the Festools moved in. I guess the truth hurts.
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Jonhilgen
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Location: Charleston, SC (USA) Member Since: Dec 2009
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« Reply #10 on: March 22, 2010, 07:24 AM » |
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Peter,
You da man. Thanks for the help. I'm going to try order some samples today to get this ball rolling.
Jon
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The more Festools I buy, the more money I earn. The more money I earn, the more Festools I buy. The more...
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Peter Halle
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« Reply #11 on: March 22, 2010, 08:46 AM » |
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Here is PDF regarding starboard:  Working_with_StarBoard2.pdf (755.32 KB - downloaded 196 times.) |
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The tools in my truck were talking the other day. The Dewalts, PC's, Boschs, Makitas were not happy. They also were in the minority. Their complaint: They felt unused and unappreciated since the Festools moved in. I guess the truth hurts.
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Jonhilgen
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Location: Charleston, SC (USA) Member Since: Dec 2009
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« Reply #12 on: March 27, 2010, 10:50 AM » |
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How do you think the Domino would work with this material(Seaboard/Starboard)? I'm going to assume that it would work fine, but I'm trying to figure out ways to "hold" my cabinets together so I can put screws in them (using the SIPO dominos) during assembly. As you can see, I'm itching to buy a Domino.
Jon
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The more Festools I buy, the more money I earn. The more money I earn, the more Festools I buy. The more...
TS 55, TS 75, Domino, CT22, OF 2000, C12, CXS, RAS, Trion, Fogtainers!
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Peter Halle
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« Reply #13 on: March 27, 2010, 11:42 AM » |
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Jon.
Starboard is a cousin of the material used for plastic cutting boards - polyethylene. The domino could certainly be used for indexing prior to mechanically fastening, but I have one concern - visibility. Before you think that I have gone nuts on you, I have never used Starboard, but I have plastic cutting boards. If I hold up one of those that appears white and is .25 inches thick to the 40 watt bulb - you can see light thru it. I wonder if the dark sipo dominos will be visible in strong light and that Starboard requires its thickness to be greater to eliminate transparency to some degree.
You might want to ask that question before you buy. I will grab a sipo domino and show you what I mean in a couple of minutes.
Peter
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The tools in my truck were talking the other day. The Dewalts, PC's, Boschs, Makitas were not happy. They also were in the minority. Their complaint: They felt unused and unappreciated since the Festools moved in. I guess the truth hurts.
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Brice Burrell
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Location: Pittsburgh, PA, USA Member Since: Mar 2007
Posts: 6186
Remodeling Contractor
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« Reply #14 on: March 27, 2010, 12:33 PM » |
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Jon.
Starboard is a cousin of the material used for plastic cutting boards - polyethylene. The domino could certainly be used for indexing prior to mechanically fastening, but I have one concern - visibility. Before you think that I have gone nuts on you, I have never used Starboard, but I have plastic cutting boards. If I hold up one of those that appears white and is .25 inches thick to the 40 watt bulb - you can see light thru it. I wonder if the dark sipo dominos will be visible in strong light and that Starboard requires its thickness to be greater to eliminate transparency to some degree.
You might want to ask that question before you buy. I will grab a sipo domino and show you what I mean in a couple of minutes.
Peter
Another thought is to make your tenons out of Starboard, visibility should be much less of a issue then. |
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Peter Halle
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« Reply #15 on: March 27, 2010, 01:04 PM » |
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Jon, Brice had a good suggestion. Here is what I meant. Sipo behind .25 in thick poly  Sipo behind .40 in thick poly  Before anyone says anything, all my cutting boards are now soaking in bleach  Peter |
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Logged
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The tools in my truck were talking the other day. The Dewalts, PC's, Boschs, Makitas were not happy. They also were in the minority. Their complaint: They felt unused and unappreciated since the Festools moved in. I guess the truth hurts.
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Jonhilgen
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Location: Charleston, SC (USA) Member Since: Dec 2009
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« Reply #16 on: March 27, 2010, 01:24 PM » |
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You guys think of everything!
Are domino tenons easy to make?
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« Last Edit: March 27, 2010, 03:25 PM by Jonhilgen »
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The more Festools I buy, the more money I earn. The more money I earn, the more Festools I buy. The more...
TS 55, TS 75, Domino, CT22, OF 2000, C12, CXS, RAS, Trion, Fogtainers!
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Jonhilgen
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« Reply #17 on: March 27, 2010, 03:26 PM » |
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You guys think of everything!
Are domino tenons easy to make?
edit: dumb question, disregard please. typing before thinking. |
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The more Festools I buy, the more money I earn. The more money I earn, the more Festools I buy. The more...
TS 55, TS 75, Domino, CT22, OF 2000, C12, CXS, RAS, Trion, Fogtainers!
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Tom Bellemare
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« Reply #18 on: March 27, 2010, 07:11 PM » |
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Peter:
You can get white poly. It's actually pretty common.
Tom
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Jonhilgen
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« Reply #19 on: March 27, 2010, 07:42 PM » |
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Jon, Brice had a good suggestion. Here is what I meant. Sipo behind .25 in thick poly [ ERROR: SPECIFIED ATTACHMENT MISSING ] Sipo behind .40 in thick poly [ ERROR: SPECIFIED ATTACHMENT MISSING ] Before anyone says anything, all my cutting boards are now soaking in bleach Peter Peter, I should have some seaboard drops once I start cutting cab parts. I'll send you a couple of new cutting boards. It's FDA approved! |
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The more Festools I buy, the more money I earn. The more money I earn, the more Festools I buy. The more...
TS 55, TS 75, Domino, CT22, OF 2000, C12, CXS, RAS, Trion, Fogtainers!
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Peter Halle
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« Reply #20 on: March 27, 2010, 07:45 PM » |
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Tom,
My concern was that white poly depended on it's thickness to be white. I guess the best way to explain is that a translucent white surface - if thick enough - would appear a solid color. But if you inserted something dark one third of the way - the amount of material in front of that dark object would not be enough to hide.
I admit that I am somewhat ignorant as to Starboard and don't know the product qualities, so I just threw that out as a consideration to check out for someone who is going to be paying a considerable amount of money for product and then doing a project for a paying customer.
I can't wait to see the ultimate results.
Peter
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The tools in my truck were talking the other day. The Dewalts, PC's, Boschs, Makitas were not happy. They also were in the minority. Their complaint: They felt unused and unappreciated since the Festools moved in. I guess the truth hurts.
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Jonhilgen
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« Reply #21 on: March 27, 2010, 07:58 PM » |
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I understand the concern about the dominos being visible, but I think since I will most likely be using them to join cabinet sides to bottoms I don't think they will be. Once the toe kicks get installed, there will be little or no light under the cabinets to backlight the starboard and highlight domino. Luckily there are no "finished" ends on any of the cabinets, just one base cabinet which will get an applied end panel. No wall cabinets either. You can bet I will test this prior to final assembly though. I can just imagine me visualizing Peter's pictures of his cutting boards in my head as the client is chewing me out about "dark spots" inside his cabinets!. I just can't think of any other way to position the materials until I get screws in them, other than clamps, but where's the fun in that?  Jon |
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« Last Edit: March 27, 2010, 08:01 PM by Jonhilgen »
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The more Festools I buy, the more money I earn. The more money I earn, the more Festools I buy. The more...
TS 55, TS 75, Domino, CT22, OF 2000, C12, CXS, RAS, Trion, Fogtainers!
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Jonhilgen
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« Reply #22 on: March 27, 2010, 08:05 PM » |
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I had cabinets made of Starboard on my last boat too. Hated them. Most of the others in the boating group also complained about Starboard. The material is easily marked yet can be tough at times to clean -- been there. But, it is easily machined with woodworking tools and will work for outdoor cabinetry.
Yeah, even the starboard salesman that was getting me quotes thought I was nuts to be using polar white in an outdoor kitchen "next to a grill?. He said once you get some oil on it, you cant hesitate to clean it. You have to jump on it right away to make sure it doesn't stain. Once I told him the color wasn't my choice, but a kitchen designer's, he knowingly chuckled and said "Typical". I foresee plenty of warranty replacement doors (charged back to the designer, of course) |
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« Last Edit: March 27, 2010, 08:07 PM by Jonhilgen »
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The more Festools I buy, the more money I earn. The more money I earn, the more Festools I buy. The more...
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Tom Bellemare
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« Reply #23 on: March 28, 2010, 04:08 PM » |
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Another product that would work, but is pretty expensive, is Richlite. It's used as counter tops and also for tooling at Boeing. It's more opaque than white poly and comes in a lot of colors.
Tom
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Jonhilgen
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« Reply #24 on: March 28, 2010, 05:55 PM » |
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Another product that would work, but is pretty expensive, is Richlite. It's used as counter tops and also for tooling at Boeing. It's more opaque than white poly and comes in a lot of colors.
Tom
Wow, haven't heard of that product for a while. Used it in a laundry room years ago, looked great. would like to use it, but the designer already sold the clients on Starboard/Seaboard. Thanks Tom. Jon |
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The more Festools I buy, the more money I earn. The more money I earn, the more Festools I buy. The more...
TS 55, TS 75, Domino, CT22, OF 2000, C12, CXS, RAS, Trion, Fogtainers!
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Jonhilgen
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« Reply #25 on: April 07, 2010, 06:24 PM » |
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Whoo hoo! Just sent the deposit invoice! Job is a go! I'll try to do my best to document it with pictures, and hopefully there will be some shiny new green tools in them...
Peter, Brice, Tom, corwin, warnerconst, and everyone else, thanks for you input. It has been invaluable.
p.s. has anyone else noticed that the more green tools you own, the more green you make, only to buy more green tools...hmmm. It's a vicious cycle that I plan on continuing.
Jon
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The more Festools I buy, the more money I earn. The more money I earn, the more Festools I buy. The more...
TS 55, TS 75, Domino, CT22, OF 2000, C12, CXS, RAS, Trion, Fogtainers!
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Peter Halle
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« Reply #26 on: April 07, 2010, 06:59 PM » |
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Jon,
Congrats on the job. Can't wait to see what you come up with!
Peter
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The tools in my truck were talking the other day. The Dewalts, PC's, Boschs, Makitas were not happy. They also were in the minority. Their complaint: They felt unused and unappreciated since the Festools moved in. I guess the truth hurts.
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Jonhilgen
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« Reply #27 on: June 24, 2010, 01:45 PM » |
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Cabinets are built and ready for install (should happen in the next month)!
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The more Festools I buy, the more money I earn. The more money I earn, the more Festools I buy. The more...
TS 55, TS 75, Domino, CT22, OF 2000, C12, CXS, RAS, Trion, Fogtainers!
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Brice Burrell
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Location: Pittsburgh, PA, USA Member Since: Mar 2007
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« Reply #28 on: June 24, 2010, 07:48 PM » |
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I was hoping you'd update us with this project. I'd love to hear more about the build and the material.
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fshanno
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« Reply #29 on: July 03, 2010, 12:31 PM » |
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Nice boxes! Looks like that job will be something you can be proud of for the rest of your life, literally. Judging from the doors you had no trouble with flatness.
I have about a zillion questions.
What size sheets did you start with?
I really like those feet. What about the hardware? Is it all stainless? Are there any drawers? If so did you make the boxes out of the starboard?
Did you cut out the parts with a TS55?
What's the countertop going to be?
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The one thing we learn from history is that we never learn from history.
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