THE ULTIMATE GUIDE
TO WORKING WITH
KING STARBOARD
TABLE OF
CONTENTS
04
What is King StarBoard
11 Cutting King StarBoard
17 Sanding & Routing
22 King StarBoard Assembly
26 Tech Specs of King StarBoard
26 Contact Us
3
WHAT IS
KING STARBOARD?
4
WHAT IS
KING STARBOARD?
King StarBoard, developed specically for the marine
environment, is a high-density polyethylene (plastic)
material, perfect for fabricating boat parts and
accessories.
It has been environmentally stabilized to withstand
the harshest marine conditions. This means that
StarBoard does not rot, swell, splinter or split when
exposed to humidity or water. It is resistant to
saltwater, UV rays, chemicals, and corrosion.
Works like wood, lasts a lifetime! StarBoard is easy to
cut and assemble with standard woodworking tools,
and requires little or no nishing.
StarBoard is easy to clean and never needs renishing.
Since its introduction, it has been the preferred boat
building material for marine parts previously made
from teak wood.
4
5
PHYSICAL
CHARACTERISTICS
StarBoard Sheet Sizes
StarBoard is fabricated by being extruded and cut into sheets
measuring 54” x 96” with the exception of sheets 1 ½” thick
measuring 48” x 96”. The edges of the material are smooth
and both the top and bottom surfaces have a durable-matte
texture.
StarBoard Sheet Thickness & Weight Chart
*Custom thickness available upon request (minimum purchase required)
Thickness (in inches)
¼” ⅜” ½” ¾” 1” 1 ½”
Weight (per sq foot) 1.25 lbs 1.875 lbs 2.5 lbs 3.75 lbs 5 lbs 7.5 lbs
6
PHYSICAL
CHARACTERISTICS
Expansion & Contraction
King StarBoard expands when it gets hot and contracts when it gets cold.
z The rate at which it expands and contracts is 1/32” per linear foot -→ for a 40º temperature change
Example: A piece of StarBoard measuring 48” long cut in a 60º→ warehouse will expand to
48.125” in 100→º weather.
While it is important to know that StarBoard does react to temperature changes, for the majority of
applications this is not a major concern.
Additional consideration should be given when:
Example: If you were installing a large door inside of a metal frame, it would be important to
allow that door enough space to expand and contract inside the frame in accordance with
temperature change.
z Working on a large product
z Installing a project that ts tightly in a conned space (i.e. a countertop between two walls)
z Cutting/installing a project in a temperature considerably lower than where it will typically
be used
z In an environment with drastic temperature changes
7
COMMON
COLORS
Available in seven standard colors to match or accent the most common
gelcoat colors. (shown below)
Important Note: Color accuracy can vary considerably on computer monitors and printers. Use the above
images as a general guide of relative color dierences. When color match is absolutely critical, please consider
purchasing a sample chain.
Note: Other colors may be available upon request
8
z Cup Holders
z Steps and Dock Boxes
z Tool holders
z Frames and Trim
z Swim Platforms
z Repurposing old plastic or teak parts
COMMON MARINE
APPLICATIONS
StarBoard is excellent for almost any application where it can be properly
supported. It is not load-bearing and may bend under its own weight
without a stiener.
Applications:
z Countertops
z Cutting Boards
z Tables
z Storage Units/Cabinets
z Grab Rails and Handles
z Hatches and Doors
9
OTHER COMMON
APPLICATIONS
z Bathroom Stalls/ Partitions
z Signage
z Lockers
z Shelving
z Wall Panels
z Decorative Ceiling Panels
z Outdoor Furniture
z Concession Stands
z Healthcare Case Goods
z Indoor and Outdoor Cabinets
z Kick Plates
z Outdoor Kitchens
z Playgrounds
z Tabletops and Counters
The applications with King StarBoard are ENDLESS!
10
CUTTING
KING STARBOARD
11
CUTTING
KING STARBOARD
Use standard woodworking tools to cut! StarBoard cuts faster and more easily than plywood or teak because
it shears instead of tearing and shredding.
Long Straight Cuts
Circular Saw
Use a sharp carbide blade with a
high tooth count (min: 60-teeth for
10”, 40-teeth for 7.5”)
Less work up front, more nishing/sanding work to clean up the edge
Use a multi-purpose blade
with a high tooth count
(min: 24 TPI)
Table Saw Jig Saw Band Saw
Small Detail Cuts
More work up front creating template,
less work on backend as the router will
provide the cleanest cut
Template Cutting
Use a carbide ush
trimming router bit with a
top bearing
Hand Router
12
CUTTING STARBOARD
BEST PRACTICES
Properly Support The Material
King StarBoard will bend if not properly supported, especially in a hot
environment. We recommend a support at least every 12” for ½” material.
Never store the material leaning against a wall as it could bend/bow.
Use Water Based Markers or Pens (Never Pencils)
Pencil marks can permanently stain the StarBoard while marker/pen
marks can typically be removed with simple household cleaners.
Don’t Go Too Slow
Aim for a feed rate of 12-16 feet per minute for ½” material (slightly slower
for thicker material). If you go too slow you risk the blade overheating
causing the material to melt back on itself.
Consider Having it Custom Cut
If you are at all concerned about your ability to manufacture, please
keep in mind that at Boat Outtters we custom cut to any size and shape
required. Give us a call at 866.633.7961 for a quote!
Supplementary Tools
Straightedge
Clamps
China or Water Based
Marker
Painters Tape
13
LONG
STRAIGHT CUTS
HOW TO:
z Measure your area accurately prior
to cutting “measure twice, cut once”
z Use a straightedge to draw your
cut line across the material to help
maintain a straight, square cut
z Support the material so it does not
ex when cutting to achieve an
accurate cut
z Blade depth adjustments can be
made to achieve a through cut or
for simply adding a groove in the
material
z Leave extra material when cutting if
a nished edge is required to allow
for routing or sanding
Circular Saw
Table Saw
PROS: Added portability due to
not being permanently axed
CONS: More dicult to achieve
consistent cuts
PROS: Added stability allows for
more consistent cuts, faster
CONS: Less portability
14
SMALL
DETAILED CUTS
HOW TO:
z Ensure all blades are sharp to avoid
a reduced feed rate which can
cause melting of the material
z To avoid veering of your line or
breaking your saw blade, add relief
cuts to allow for easier transitions
z Protect the surface of the material
from the table base and guides
to avoid marring of the material
(masking tape can be used)
z Use clamps to avoid shifting of the
material while cutting
z Drill or cut access holes as a starting
point to enter the material when
necessary
z Usage of a jig or fence is
recommended for consistency of
cuts where possible
Jig Saw Band Saw
PROS: Added portability due to
not being permanently axed,
and able to make internal cuts to
surface
CONS: More dicult to achieve
consistent cuts
PROS: Added stability allows for
more consistent cuts
CONS: Less portability, not able to
make internal cuts
A jigsaw or bandsaw work best when cutting irregular shapes
15
HOW TO:
z Create an exact replica template of the part (cut, trim, sand to t)
z Once conrmed, clamp the template to oversized StarBoard and trim
around template using a ½” shank double uted ush trim router bit
z Top or bottom bearing bits acceptable
z Ensure your cut depth extends ¼” below the StarBoard for a clean
consistent cut
Hand Router
Flush Trim Router Bit
PROS: Cleanest Finished Edge
CONS: More upfront work due to
building a template
TEMPLATE
CUTTING
16
SANDING
& ROUTING
17
SANDING & EDGE FINISHING FOR
KING STARBOARD
Sanding or routing the edges of StarBoard is not always needed as a clean cut will produce a clean edge.
However, if you need to smooth out a jagged cut or desire a certain edge, these standard woodworking tools
can help you achieve that.
SANDING
ROUTING
Orbital Sander/Sandpaper Wheel
Hand Router
Use 100-150 grit sandpaper wheel or orbital sander
Hand-sanding the edge is also an option
Use a carbide roundover router bit with bottom bearing
Regardless on style of sanding, be sure to use very ne
sandpaper to avoid creating small, hard-to-clean scratches
Bit size will be determined on thickness of material and
desired edge nish
18
SANDING
STARBOARD
Sanding the Edges
(Cleaning Up a Rough Cut)
The edge of StarBoard can be sanded with an orbital sander
or hand sander to help smooth out a jagged edge.
KEEP IN MIND:
z Sanding can produce small grooves and stroke marks (smaller grit helps
limit these)
z It is recommended that if you choose to sand the edge that you then sand
all the edges to give your project a uniform look
SANDING THE EDGE:
19
Sanding the Surface
(Removing a Scratch)
We DO NOT recommend sanding the surface of StarBoard!
KEEP IN MIND:
z Surface of StarBoard comes with a uniform matte nish on both sides
z Sanding anywhere on the surface of StarBoard will cause it to lose its uniform matte nish
z Result: Sanding the surface will result in a non-uniform textured surface and marring of
the nish
SANDING THE SURFACE:
20
EDGE ROUNDOVERS ON
STARBOARD
Finishing the edges of StarBoard with a router is easy
and can be achieved by using a standard roundover bit.
KEEP IN MIND:
z To leave a nice clean edge, StarBoard material needs to be thicker
than your router bit. This allows the bearing to have good contact
with the StarBoard when routing.
} For example: routing ¼” sheet of StarBoard would
require a 3/16” or smaller router bit
z A carbide roundover bit is recommended
} Bit size is determined upon sheet thickness and desired
edge
21
KING STARBOARD
ASSEMBLY
22
KING STARBOARD
ASSEMBLY
King StarBoard is easy to assemble using standard woodworking tools. You should use mechanical fasteners
(screws, bolts, or threaded inserts) to secure it together.
KEEP IN MIND:
Gluing King StarBoard is NOT recommended!
REQUIRED TOOLS
SUPPLEMENTARY TOOLS
Hand Drill and Bits
Pocket Hole Jig
Threaded Inserts
Rubber Mallet
Starboard Plugs
23
z Use a water based marker/pen to mark StarBoard
} Pencil marks do not wipe o and can gouge material
z Always drill pilot holes for better screw retention
z When screwing into the edge (i.e. “end grain”), your material must be
at least ⅜” thick
Screw Size Pilot Hole Thru Hole
#4 5/64” 1/8”
#6 7/64” 5/32”
#8 1/8” 3/16”
#10 1/8” 7/32”
#12 9/64” 15/64”
#14 5/32” 17/64”
Basic StarBoard Assembly Tips
Pilot Hole to Screw Size Chart
24
Advanced StarBoard Assembly Techniques
HIDING FASTENERS:
z Pocket hole jigs angle screws and help to hide them from view
z You can hide counter-bored screws by hammering StarBoard plugs into the holes
using a rubber mallet
WELDING:
z You can weld King StarBoard using a plastic hot air welder. Welding StarBoard fuses
together two surfaces and creates a waterproof seam
} Welding StarBoard can be challenging insomuch that you are unable to
sand down the welds (like welding metal) to create a smooth nished seam
SCREW RETENTION:
z Threaded inserts can be used to ensure screw retention and avoid stripping material
in locations where a fastener may be frequently added and removed
ADDITIONAL ASSEMBLY:
z Dado or Rabbet cuts can be added at joints for additional strength and ease of
assembly/alignment
z A hand router with a Dado or Rabbet bit can be used to cut a notch before attaching
pieces together
25
SAFETY MEASURES
BEST PRACTICES
Wear Safety Equipment
It is important that the proper safety equipment is worn when using tools
to cut and assemble King StarBoard.
Making sure you wear the proper safety equipment and checking that
your safety equipment is undamaged signicantly lowers your likelihood
of getting injured.
No one wants to get hurt, so by checking that you have the proper
equipment to protect you, you can better keep yourself safe!
Refer To Manufacturer’s Instructions
Please refer to the manufacturer’s instructions/safety manual for each
piece of equipment to review all the safety precautions for each tool.
The manufacturer’s instructions provide you with the knowledge on how
to properly protect yourself from injury with these tools.
Supplementary Tools
Safety Glasses
Ear Protection
Dust Mask
26
Properties Units
ASTM
Nominal Values
Density g/cc D1505 0.955
Tensile Strength @ Yeild psi D638 >4,100
Tensile Modulus psi D638 255,000
Elongation @ Break % D638 >600
Elongation @ Yield % D638 9.8
Flexural Modulus psi D790 185,000
Flexural Stress @ 5% Strain psi D790 3,810
Compressive Properties 10% Strain psi D695 4,950
Durometer Shore D D2240 68
Tensile Impact ft.lbs./in.² D1822 115
Izod Impact Resistance ft.lbs/in.² D256 1.1
Brittleness Temp. ºC (ºF) D746 <-76ºC (<-105ºF)
Vicat Softening Temp ºC (ºF) D1525 123ºC (253ºF)
Heat Deection Temp. 66 psi ºC (ºF) D648 75ºC (167ºF)
Screw and Nail Withdrawal lbs D1761 657 & 63
Flammability Rating UL94 HB
KING STARBOARD
PHYSICAL PROPERTIES SPEC SHEET
FOR MORE INFORMATION OR
ADDITIONAL QUESTION
CONTACT US
