King Starboard Projects/Accessories, post your work or ideas!

[Charlie98117]

I used it to cover holes from old instruments in the cockpit bulkhead. I replaced old depth and knot meters with a small multifunction display so had a lot of area to cover. I came up with a 1/2" thick panel that followed the lines of the boat and added a mirror image one to the other side for symmetry. Installed with screws from the inside so no exposed fasteners. Sort of almost looks factory.
Before After

I've since then added more electronics and moved everything to the helm so I made a new blank panel.

 

[thinwater]

My only reservation is its tendency to creep. I've used it for filler and light mounting blocks, but never with real loads.
(1/4-inch bolt overnight)

 

[JamesG161]

One thing I learned from doing so is that starboard, and I assume the others, contract and expand to a significant degree with the temperature. One should keep that in mind if installing something in a cooler climate then sailing off to the warmth of the tropics.

A 30" tall hatch would grow 0.2 inches in a swing of 100° F swing.
Jim...

 

[CloudDiver]

This is strange.... Doesn't HDPE stand for 'High Density Polyethylene'? Maybe there are different 'grades' that should be considered depending on application?

My only reservation is its tendency to creep. I've used it for filler and light mounting blocks, but never with real loads.
(1/4-inch bolt overnight)

 

[Terry Cox]

P42 stern rail seat.

http://hunter.sailboatowners.com/mods.php?task=article&mid=45&aid=6401&mn=42
http://hunter.sailboatowners.com/mods.php?task=article&mid=45&aid=7577&mn=42
http://hunter.sailboatowners.com/mods.php?task=article&mid=45&aid=7603&mn=42

 

[Ken13559]

are these going to on the shelves by Christmas?

 

[Maine Sail]

I build these for a lot of customers and they rave about them. Simple, clean and no big white box...

While UV stable HDPE is a good product it is far from perfect and there are a lot of applications I would never use it for. One of them is for backing plates, not stiff enough and sealant won't stick well to it, and the other is for clutch or winch pads. As Thinwater pointed out "creep" is a real problem for high loads with HDPE.. Even 5200 does not like to stick to it for long and they will eventually leak. I have seen this on far too many occasions to count. A previous owner, or boat yard, had used it on one of my own boats for clutch pads, and it leaked. I had a customer a few years ago had new Seacocks installed in Florida. By the time he got to Maine 4 of the 6 installed were leaking around the HDPE backing plates. The whole job had to be re-done at huge expense. I've learned my lessons on HDPE for backers and now use G-10.

Also up here in the great white North I see far to many improperly drilled screw holes crack when the temp drops. Great stuff in the right application bad stuff for the wrong application...

 

[JamesG161]

This is strange.... Doesn't HDPE stand for 'High Density Polyethylene'? Maybe there are different 'grades' that should be considered depending on application?

High Density PolyEthylene is actually clear at the production factory. The clear HDPE is the sold to companies that put different compound, mixing them in a Melt and then extruded to forms, pipe, slabs, etc.
The Starboard® has a proven marine compounding. If you add color pigments you can get different shades.

Great stuff in the right application bad stuff for the wrong application...

So true...

I have used HDPE as a load spreader, kinda like a washer, many times. The modulus of 3/8th thick Starboard® is same as a 1/4" SS plate in my application.
You must know your load to know how thick the Starboard® should be. Also only certain adhesives work on HDPE ( as any plastic ). Creep is also load/thickness dependent. Temperature of operation for expansion, may eliminate StarboardR®.
Jim...

PS: In my day I manufactured HDPE and LDPE.

 

[Curious Sailor]

1" Starboard (HDPE). Cut with skilsaw, jigsaw, and finished with files (not sandpaper)
Counter sunk holes for SS carriage bolts, thru to backing plates.
The supports are Starboard fitted to the contours of the bow, 3M 5200 sealant.
The supports are fastened with 2.5" #10 SS screws in countersunk holes from beneath.

This is awesome! I have been scratching my head for the longest time wondering how I was going to make a bow pulpit and I may have just found my answer. Thank you! Are the supports fastened to the bow also or just butted and sealed?

 

[capta]

So what is the glue that works with Starboard?

 

[JamesG161]

So what is the glue that works with Starboard?

Open my big mouth and now to put my foot in there.

Adhesives are designed to Bond material like A and B together for a Service. A + B = AB or A+A = AA
We clean surfaces to make sure A + B +d+g ≠ AdBg d=dirt g=grease.
Guess what, HDPE, LDPE, or any PolyEthylene is so chemical resistant it has been a tough to glue them. HDPE+HDPE = heat welding.

http://www.tapplastics.com/product/repair_products/plastic_adhesives/tap_poly_weld_adhesive/435
Claims success, but others seem to back them up. Tap Plastic Company seems very reputable.

This site is good since they also sell A,B,C, etc and their adhesives.
http://www.eplastics.com

Do you believe in Big Foot? Well here is proof (opens my mouth wider)

What is the SERVICE?

Which was the point of my post #28 adding to Maine Sail's point of finding (perhaps the hard way) ways NOT to use Starboard®.

The great boat projects in this post are mainly, plates, boxes, shapes, or accessories. PE water tanks and other higher Service needs are extruded, spun moulded, melt injected, or welded and NOT glued.

I was once told by a world class expert....
"You can BOND anything to Anything!"
So, capta... What are your service requirements?
Jim...

 

[capta]

Open my big mouth and now to put my foot in there.

Adhesives are designed to Bond material like A and B together for a Service. A + B = AB or A+A = AA
We clean surfaces to make sure A + B +d+g ≠ AdBg d=dirt g=grease.
Guess what, HDPE, LDPE, or any PolyEthylene is so chemical resistant it has been a tough to glue them. HDPE+HDPE = heat welding.

http://www.tapplastics.com/product/repair_products/plastic_adhesives/tap_poly_weld_adhesive/435
Claims success, but others seem to back them up. Tap Plastic Company seems very reputable.

This site is good since they also sell A,B,C, etc and their adhesives.
http://www.eplastics.com

Do you believe in Big Foot? Well here is proof (opens my mouth wider)

What is the SERVICE?

Which was the point of my post #28 adding to Maine Sail's point of finding (perhaps the hard way) ways NOT to use Starboard®.

The great boat projects in this post are mainly, plates, boxes, shapes, or accessories. PE water tanks and other higher Service needs are extruded, spun moulded, melt injected, or welded and NOT glued.

I was once told by a world class expert....
"You can BOND anything to Anything!"
So, capta... What are your service requirements?
Jim...

Jim, thank you for the concise answer. Most of the projects I would like to use Starboard for are like this pump hanger,

using glue for parts like the support under the upper pump platform. Even gluing shelves of starboard onto starboard for locker dividers and can goods stowage.
So mostly interior stuff with low stress applications.
Thanks.

 

[JamesG161]

So mostly interior stuff with low stress applications.

If you watch the "How to" video on the Tap Plastic link on my Post #31, their technic, although complex, should meet your described service.

BTW nice design and craftsmanship on your photo job above. I wish I had that talent.

The bonding video demoed a bonding shear load ( a load parallel to the edge) for at least 150 pounds. The tech data sheet touted 2000 pound bonding shear. This company is serious about their bonding agent (not a classic glue) on that link.

In critical or safety needed loads, I might pre-drill for a counter sunk, brass (SS steel is ok) wood screws ( the more the combined, embedded screw threads the more the load secured). That would make the thickness of Starboard® for support loads thicker than the dividers.
Example: The Admiral wants shelves to put shelves to divide 40 cans of liquid, 16oz size. The shelf base may be 1/2" thick Starboard® and the dividers 1/4" thick.
Report back if you use this bonding technique. I wanted to order a $16 size tube.
Jim...

 

[capta]

Thanks Jim. It may be some time before I can even get the glue sent down here as the season is beginning and we'll be moving quite a bit, but I'll get back when I've tried it.
As for the attached pic, I'd love to say that it is my work, but the craftsman in this case is Cloud Diver. I agree, it is a magnificent bit of craftsmanship.http://forums.sailboatowners.com/index.php?members/clouddiver.127132/

 

[CloudDiver]

I can't take credit for those pics I posted to start the thread, those were various examples of projects I google searched to start the thread. If you reverse image search that pump hanger I'm sure you would find out to whom credit is due.

For the boat I am working on now these pics of a hinged electrical panel on a C-22 is the only thing I have recently done in King Starboard; When I install the panels it should have a horizontal 6 gang switch/breaker panel and another 4 gang switch panel to individually switch the Anchor light/steaming light/fore-deck light on the mast. Trying to squeeze in a couple 12V power sockets and a voltmeter if I can.

Thanks Jim. It may be some time before I can even get the glue sent down here as the season is beginning and we'll be moving quite a bit, but I'll get back when I've tried it.
As for the attached pic, I'd love to say that it is my work, but the craftsman in this case is Cloud Diver. I agree, it is a magnificent bit of craftsmanship.

 

[thinwater]

This is strange.... Doesn't HDPE stand for 'High Density Polyethylene'? Maybe there are different 'grades' that should be considered depending on application?

No, this is normal for all grades. This was under substantial clamping pressure (I am researching backing plate materials for an up-coming article) and wold not happen in most applications. But if you need bolts at full torque, it won't work well unless there is a lot of clamping pressure. Micro cracks also started on the underside after a month.

I do use this stuff for many projects. It is perfect for many things.

 

[JamesG161]

full torque

Torque is applied to make bolts stretch and hold in tension. Spread that fixed load with a washer. The modulus of of Starboard® is very high for a plastic. It is not torque but ultimate load.
I have two bolts to hold a stanchion post for life rail. The fiberglas deck is the load bearing part, the backer is just a washer (in effect) to spread the load of the stanchion to the hull.
You should use lock-tight or lock washer to hold nut and don't over torque the bolt. Just snug tight, and a 1/4 turn more ( unless there is alignment or a compression spring). Spread the bolt load with a very big washer or stacked for hole diameter of 2 washers.

My stanchion should support 1500 lbs bending load, minimum. That load is spread over a 8x4 inch plate or 32 sq inches which is 49 lb/sq inch ( same as a 200 lb man standing on one heel), no biggie for Starboard® or hull to take, and it won't creep, since the load is minor normally.

Use it for just about any plastics service.
Jim...