Using Starboard

[RickK]

http://www.classicaquasport.com/gallery/showphoto.php/photo/1100/sort/1/cat/500/page/2 (Don't know why the img commands don't work)
I want to build a backrest for the seat in front of my console and didn't want to use a product that would require a lot of maintenance. I bought a 24x27 piece of starboard (boy are they proud of this stuff   ) and in reading the little book they give you, I found that the only way to glue this stuff to itself is with a 2-part epoxy - 3M DP-8005.  They say that even 5200 will not stick to it.  The backrest I've designed will standoff the console about 4" and I want to reinforce the corners by glueing in braces. Plus, I think that glueing all the pieces together will make it stronger, structurally.
Here's my dilemma, I have found a couple web sources (nothing locally yet) of the DP-8005 and this stuff is not cheap.  The applicator gun is $50 and each 1.5ounce tube is approx $18.  The kicker is that they sell the tubes in case (12) only.
Somewhere else I read that there is another way to secure it - you can burn the starboard with a torch and then use some kind of hot glue - unfortunately they didn't go into much detail.
Any ideas guys?

[John Jones]

I remember reading the torch thing somewhere.  I'll try to remember where but at my age memory is not one of my strong points.  :cry:

5200 nor anything else I know of will stick to Starboard.  I was not about to pay the price for the 3M stuff.  When I use it, I pre-drill and screw it.  I am not impressed by Starboard for most applications.  The manuf. says to not use it in structural applications.  My biggest gripe is that once it gets dirty, it's dirty forever.

[RickK]

Good points to consider.
I cut just the booklet out of the package so far, so I can probably take it back.  I read that just about anything stains it (lead pencil, permanent marker, etc). Too bad they can't make a glue that is made out of the stuff that stains it.   I don't think, in my application, it should get dirty though.  I'm afraid that side-to-side pressure will collapse this backrest if I can't glue it and only screw it.  I could mortise it into each other and then screw it??
Is there any other type product out there that is waterproof and lllloooowwww maintenance?

[JimCt]

Can you make the backrest out of plywood and then 'glass & paint it?  Might be the simplest.  For a completely unrelated application at work we considered using Starboard but rejected it because of the problem bonding it.  It appears to be like Nylon or Delrin which are difficult to bond to.

[RickK]

I don't know how they can sell it for any type of project except flat!!  Everyone must freak when they see the price of the glue & applicator - and I read that the glue only has a 6 months shelf life on it so I guess that is why they want to sell you a case - to keep turning stock over.

Can you make the backrest out of plywood and then 'glass & paint it?  Might be the simplest.

 
I hope it doesn't come to that.  When I mix gelcoat it's a one shot deal (no recipes on color) and could never match existing because of the fade.  If I built it out of wood, glass and gelcoat so that everything matched, I'd have to recolor my console (wife's been after me to do it in maroon but I'm afraid of the quick fade) - unless I went with a white gelcoat since it's going to be mostly covered with cushion (except the sides).  Who knows - kind of a bummer though.

[JimCt]

Why not finish coat it with 2 part urethane?  You'd be able to match whatever color you want.  If you roll & tip it the finish should come out quite well.

[RickK]

Urethane doesn't do too well in fla sun.  So if I don't have to coat it with anything, I would be happier.