Need to build exterior kitchen cabinets...

J

Jonhilgen

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Joined
Dec 26, 2009
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1,113
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
 
If you use azek, sand the cut edges with 180 and paint them. 
They now have s4s azek, not sure about the sheets though.
 
Peter Halle said:
Does Starboard ring a bell?

Peter
Click to expand...

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.

 
WarnerConstCo. said:
If you use azek, sand the cut edges with 180 and paint them. 
They now have s4s azek, not sure about the sheets though.
Click to expand...

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!
 
Regarding Starboard, here is a place that will do custom fabrication:  www.buckwoodcraft.com/custom_woodworking.htm

Their 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%7E305

Check 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
 
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.
 
Jonhilgen said:
WarnerConstCo. said:
If you use azek, sand the cut edges with 180 and paint them. 
They now have s4s azek, not sure about the sheets though.
Click to expand...

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!
Click to expand...

I was talking just about the cut edges.  Trust me, you can't tell they are painted.

The sheets can remain factory white.
 
Peter,

You da man.  Thanks for the help.  I'm going to try order some samples today to get this ball rolling.

Jon
 
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
 
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
 
Peter Halle said:
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
Click to expand...

Another thought is to make your tenons out of Starboard, visibility should be much less of a issue then. 
 
Jon,

Brice had a good suggestion.  Here is what I meant.

Sipo behind .25 in thick poly

[attachimg=#]

Sipo behind .40 in thick poly

[attachimg=#]

Before anyone says anything, all my cutting boards are now soaking in bleach  ;D

Peter
 
Peter Halle said:
Jon,

Brice had a good suggestion.  Here is what I meant.

Sipo behind .25 in thick poly

[attachimg=#]

Sipo behind .40 in thick poly

[attachimg=#]

Before anyone says anything, all my cutting boards are now soaking in bleach  ;D

Peter
Click to expand...

Peter,

I should have some seaboard drops once I start cutting cab parts.  I'll send you a couple of new cutting boards.  ;D  It's FDA approved!
 
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