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Buck Woodcraft

120 49th Street, Marathon, Fl.   33050

Phone: 305-743-4090

Fax: 305-743-2951

Business Hours:

9 a.m. - 4 p.m. EST. Monday thru Friday

E-Mail:  john@buckwoodcraft.com

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Starboard Application Tips

BS 1088 Plywood

The following are brief excerpts from the full BS 1088 specification, and this material is for your general information only.

BS 1088 Specification -- This standard applies to plywood produced with untreated tropical hardwood veneers that have a set level of resistance to fungal attack. The plies are bonded with WBP glue. The finished product doesn't have to be "British made".

WBP Glue Line -- BS 1088 plywood must use an adhesive proven to be very resistant to weather, micro-organisms, cold and boiling water, and steam and dry heat. The product's bonding  must pass a series of British Standard tests.

Face Veneers -- These must present a solid surface that is free from open defects. Face veneers must be free of knots other than "sound pin" knots, and there can be no more than an average of two such knots per square foot over the entire surface of the plywood sheet. The veneers must be reasonably free from irregular grain. The use of edge joints is limited, and end joints are not allowed.

Core Veneers -- Core veneers have the same basic requirements as face veneers, except that small splits are allowed, and there is no limit on the number of pin knots or edge joints. However, end joints are not permitted.

Limits of Manufacturing Defects -- Defective bonds, pleats and overlaps, and gaps in faces are not permitted. Occasional gaps may be repaired using veneer inserts bonded with the proper adhesive.

Moisture Content -- BS 1088 plywood must have a moisture content between 6% and 14% when it leaves the factory.

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StarBoard Application Tips

This material is drawn from product-use information supplied by King Plastic Corp.

No Special Tools Required

King StarBoard is designed for fabrication using standard woodworking tools, such as table saws, table routers, drills, blades and bits.

Routing Use router bits with two to four flutes. These bits allow chips to clear the cutting surface so things don't get all gummed up. A 1/2" bit will allow a feed rate of 12' to 16' per minute for material less than 1/2" thick. Routing thicker material will require slower feed rates. A standard RPM setting is fine for 1/2" OD bits, but larger bits have higher tip speeds and may require RPM adjustments.

Sawing You'll get a nice, crisp edge if you use a good carbide blade with 50 to 70 teeth, turning at 1,275 RPM. Expect a feed rate of 12' to 16' feet per minute.

Finishing King StarBoard leaves the factory with a textured matte surface on both sides, and requires no finishing. Properly routed edges are very smooth and need no further attention. If necessary, sawn edges can be smoothed with a sanding wheel using 100 to 150 grit paper--but your smoothest finish will be achieved using router bits or any tool with a knife, such as a block plane or power plane.

Installing King StarBoard

Fastening You can attach King StarBoard to other surfaces using standard fasteners and/or StarBond Adhesive.

For standard screw fasteners, drill pilot holes in the materials to be joined, followed by oversized holes in the StarBoard to allow for expansion and contraction.

StarBoard polymers contract and expand about 1/32" for every linear foot of length or width over a 40 deg. F. temperature range. If oversized fastener holes aren't used, materials installed at low temperatures may bow when they warm up, and materials installed at warm temperatures may crack when temperatures fall--and the fasteners may bend or shear.

You can countersink and hide fasteners with StarBoard plugs, using a standard wood plug cutter. Plugs will be slightly larger than the hole size, and are simply pressed in.

Repetitive Motion Applications Installations that involve repetitive motions--door hinges come to mind--should use press-in threaded inserts for maximum strength over time.

Curves Apply mild heat to help mold StarBoard around curves. Sharp corners must be permanently heat-shaped in advance, or notched and bent after heating.

Storing And Handling King StarBoard

Storage StarBoard is shipped flat and should be stored flat. Marine-grade polymers can cold-flow, and should not be left in a position where humps or curves can develop over time.

Care And Handling King StarBoard is shipped with a poly masking sheet that protects the material from stains and abrasion during fabrication. Leave the masking in place until your work is completed.

StarBoard resists most stains, but there are some precautions you need to keep in mind:

Teak Oil can cause permanent stains, so be very careful when using it around your StarBoard installations.

Lead pencils, pens and magic markers are no-no's. They can leave a permanent discoloration, so use China markers or wax pencils instead when doing layout or other marking on the surface of StarBoard products.

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