THE ULTIMATE GUIDE

TO WORKING WITH
KING STARBOARD
 04 What is King StarBoard

TABLE OF
CONTENTS 11 Cutting King StarBoard

17 Sanding & Routing

22 King StarBoard Assembly

26 Tech Specs of King StarBoard

26 Contact Us
 WHAT IS
KING STARBOARD?

3
WHAT IS
KING STARBOARD?

King StarBoard, developed specifically 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 finishing.

StarBoard is easy to clean and never needs refinishing.

Since its introduction, it has been the preferred boat
building material for marine parts previously made
from teak wood.

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 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

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

*Custom thickness available upon request (minimum purchase required)

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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:

z Working on a large product

z Installing a project that fits tightly in a confined 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

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.

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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 differences. When color match is absolutely critical, please consider
purchasing a sample chain.

Note: Other colors may be available upon request

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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 stiffener.

Applications:
z Countertops z Cup Holders
z Cutting Boards z Steps and Dock Boxes
z Tables z Tool holders
z Storage Units/Cabinets z Frames and Trim
z Grab Rails and Handles z Swim Platforms
z Hatches and Doors z Repurposing old plastic or teak parts

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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!

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 CUTTING
KING STARBOARD

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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 Small Detail Cuts Template Cutting

Circular Saw Table Saw Jig Saw Band Saw Hand Router

Use a sharp carbide blade with a Use a multi-purpose blade Use a carbide flush
high tooth count (min: 60-teeth for with a high tooth count trimming router bit with a
10”, 40-teeth for 7.5”) (min: 24 TPI) top bearing

More work up front creating template,

Less work up front, more finishing/sanding work to clean up the edge less work on backend as the router will
provide the cleanest cut

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CUTTING STARBOARD
BEST PRACTICES
ˆ Properly Support The Material

King StarBoard will bend if not properly supported, especially in a hot

Supplementary Tools 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.

ˆ 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.

Straightedge Clamps
ˆ 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.

ˆ Consider Having it Custom Cut

China or Water Based Painters Tape
Marker If you are at all concerned about your ability to manufacture, please
keep in mind that at Boat Outfitters we custom cut to any size and shape
required. Give us a call at 866.633.7961 for a quote!

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LONG
STRAIGHT CUTS

HOW TO:
z Measure your area accurately prior Circular Saw Table Saw
to cutting “measure twice, cut once”

z Use a straightedge to draw your PROS: Added portability due to PROS: Added stability allows for
cut line across the material to help not being permanently affixed more consistent cuts, faster
maintain a straight, square cut
CONS: More difficult to achieve CONS: Less portability
z Support the material so it does not
consistent cuts
flex 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 finished edge is required to allow
for routing or sanding

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SMALL
DETAILED CUTS

HOW TO:
z Ensure all blades are sharp to avoid
a reduced feed rate which can Jig Saw Band Saw
cause melting of the material

z To avoid veering of your line or PROS: Added portability due to PROS: Added stability allows for
breaking your saw blade, add relief not being permanently affixed, more consistent cuts
cuts to allow for easier transitions and able to make internal cuts to
surface CONS: Less portability, not able to
z Protect the surface of the material make internal cuts
from the table base and guides CONS: More difficult to achieve
to avoid marring of the material consistent cuts
(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

A jigsaw or bandsaw work best when cutting irregular shapes

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TEMPLATE
HOW TO:
CUTTING
z Create an exact replica template of the part (cut, trim, sand to fit)

z Once confirmed, clamp the template to oversized StarBoard and trim

around template using a ½” shank double fluted flush 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

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 SANDING
& ROUTING

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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

Use a carbide roundover router bit with bottom bearing
Hand-sanding the edge is also an option

Regardless on style of sanding, be sure to use very fine Bit size will be determined on thickness of material and
sandpaper to avoid creating small, hard-to-clean scratches desired edge finish

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SANDING SANDING THE EDGE:

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

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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 finish on both sides

z Sanding anywhere on the surface of StarBoard will cause it to lose its uniform matte finish

z Result: Sanding the surface will result in a non-uniform textured surface and marring of
the finish

SANDING THE SURFACE:

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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

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KING STARBOARD
ASSEMBLY

21
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: SUPPLEMENTARY TOOLS

Gluing King StarBoard is NOT recommended!

REQUIRED TOOLS

Pocket Hole Jig Rubber Mallet

Threaded Inserts Starboard Plugs

Hand Drill and Bits

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Basic StarBoard Assembly Tips
z Use a water based marker/pen to mark StarBoard

} Pencil marks do not wipe off and can gouge material

Pilot Hole to Screw Size Chart
z Always drill pilot holes for better screw retention

z When screwing into the edge (i.e. “end grain”), your material must be
Screw Size Pilot Hole Thru Hole
at least ⅜” thick

#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”

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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 finished 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

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SAFETY MEASURES
BEST PRACTICES
ˆ Wear Safety Equipment
Supplementary Tools 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 significantly 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!
Safety Glasses Ear Protection
ˆ 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.

Dust Mask

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KING STARBOARD
PHYSICAL PROPERTIES SPEC SHEET

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 Deflection Temp. 66 psi ºC (ºF) D648 75ºC (167ºF)

Screw and Nail Withdrawal lbs D1761 657 & 63

Flammability Rating UL94 HB

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FOR MORE INFORMATION OR
ADDITIONAL QUESTION

CONTACT US