I need to replace the port side bulkhead on a Catalina 25. Currently it is a teak plywood. Teak plywood is hard to find in my area, outside the area it is available but shipping costs as much as the teak. I do have a local source for Starboard. I have used it before on boats but not in a structural application like this. Anybody used it in a bulkhead application? I know more newer boats are using Starboard instead of teak but on a bulkhead where the chain plate will connect? Will it be structurally sound? This bulkhead will be 4'x4' by 1/2 inch. Thanks LD
using starboard to replace a teak bulkhead
- Thread starter ldstrait
- Start date
- Status
The size and thickness of starboard you would need to equal the structural integrity of the same size plywood is likely to be more expensive than the marine ply. It also will move more than plywood which is not good for structural applications.
Starboard..
King Starboard or any of it's imitators is not a structural product! Besides that almost nothing will stick to it so tabbing in a bulkhead is nearly impossible.
If you can't get teak ply any marine grade or high quality exterior grade (no void) plywood will work. A new sheet of teak ply won't match your existing bulkhead anyway without some serious time in the stain/color matching department.
You can always paint the bulkheads white and go for the Hereshoff look.
Starboard is basically a decorative product, and a great one, but should be reserved for applications where it is not under load or stress. You can bend a sheet of 3/4" Starboard very, very easily while a sheet of multi-ply high quality plywood is very, very stiff by comparison.
I had to add those stainless struts to my pedestal guard table as even the weight of my instruments, on that short span, was bending it.. Imagine a span 6+ feet!!!
King Starboard or any of it's imitators is not a structural product! Besides that almost nothing will stick to it so tabbing in a bulkhead is nearly impossible.
If you can't get teak ply any marine grade or high quality exterior grade (no void) plywood will work. A new sheet of teak ply won't match your existing bulkhead anyway without some serious time in the stain/color matching department.
You can always paint the bulkheads white and go for the Hereshoff look.
Starboard is basically a decorative product, and a great one, but should be reserved for applications where it is not under load or stress. You can bend a sheet of 3/4" Starboard very, very easily while a sheet of multi-ply high quality plywood is very, very stiff by comparison.
I had to add those stainless struts to my pedestal guard table as even the weight of my instruments, on that short span, was bending it.. Imagine a span 6+ feet!!!
LD:
What is your purpose for wanting to use polyboard vs. plywood? If it is because you want a white finish, you should consider a exterior grade plywood with formica on the visible side.
As
What is your purpose for wanting to use polyboard vs. plywood? If it is because you want a white finish, you should consider a exterior grade plywood with formica on the visible side.
As
Starboard is not a structural material and they say as much in their own literature. It isn't stiff enough to work as a bulkhead. Also, Maine Sail's point about almost nothing sticking to it with any real degree of success is a very valid one. It is also quite heavy and expensive.
IMHO, you'd be far better off making the bulkhead out of marine plywood.
If you want something lighter you can always make the bulkhead out of high-density rigid foam, like Divinylcell and glass, by laminating a big flat sheet of it and then cutting it to fit. This might be easier to do than making the bulkhead out of plywood, since you could put the foam up and cut it to size far more easily than you could the plywood, then lay it out flat and laminate the fiberglass to it.
IMHO, you'd be far better off making the bulkhead out of marine plywood.
If you want something lighter you can always make the bulkhead out of high-density rigid foam, like Divinylcell and glass, by laminating a big flat sheet of it and then cutting it to fit. This might be easier to do than making the bulkhead out of plywood, since you could put the foam up and cut it to size far more easily than you could the plywood, then lay it out flat and laminate the fiberglass to it.
When I needed to make a new bulkhead for Bietzpadlin I prepared 1x12 cypress and laid the boards out on a table, marked the shape. and cut it out . Then I carried one plank at a time up and fitted it into place. When I was satisfied I edge glued the boards and fastened battens across the width with screws.
Go to a place that does miillwork and or stair parts. They can find and/or order some teak plywood for you. I usually go into places like that if a have small projects... theres always stuff kicking around that they will give you. If they know you are looking for something... they can trow it in the corner for you.
Ix-nay on the Starboard... do it right.
Plywood
I'd use marine plywood.
If I wanted it to look like teak, then I'd cover the visible area in veneer.
That would also let you make the bulkhead in two pieces if getting a 4x4 piece through the companionway is a problem.
I think if you look back a few months in the archive someone posted a good source for the veneer.
I'd use marine plywood.
If I wanted it to look like teak, then I'd cover the visible area in veneer.
That would also let you make the bulkhead in two pieces if getting a 4x4 piece through the companionway is a problem.
I think if you look back a few months in the archive someone posted a good source for the veneer.
Bouter plywood is a great source for veneer. Heat Lock glue is excellent for laminating a large area without contact cement or a vacuum press. I prefer wood backed veneer.
http://www.boulterplywood.com/
http://www.veneersupplies.com/advanced_search_result.php?keywords=lock
Here is some veneer that I replaced last year:
http://www.boulterplywood.com/
http://www.veneersupplies.com/advanced_search_result.php?keywords=lock
Here is some veneer that I replaced last year:
Attachments
I'd second Boulter Plywood, but I might be a bit biased, since it is only about 20 minutes from where I am. 
Starboard is not a good choice for a bulkhead. Marine plywood is your best choice and of course, to match the rest of the wood, you want teak. Marine plywood has waterproof glues superior to other grades of plywood. Exterior plywood used in houses is not a good choice (and you can't get it with a teak veneer). Regular plywood is not a good idea at all. Bulkheads are usually "tabbed" with fiberglass to the hull and possibly elsewhere. You cannot attach fiberglass to starboard plastic. When you do fiberglass your marine teak plywood, you want to remove the teak veneer at the edges so that you fiberglass the underlying surface for best adhesion. Don't use Starboard. It sounds like you are looking for an easy fix to a integral and structural part of your boat. You don't want to cut corners with this sort of repair.
- Status