Instructions / Assembly

King Plastic Corporation
1100 N. Toledo Blade Blvd., North Port, FL 34288 USA
TEL: [phone] FAX: [phone]
www.kingstarboard.com
Fabrication and Finishing
• Use standard woodworking tools: table saws, table routers, drills, blades and bits.
Carbide router bits with two to four flutes are recommended.
• With a 1/2” diameter router bit, feed rates of 12-16 feet per minute are normal.
Rates must be slower for material that is 1/2” thick or thicker. Larger bits have higher
tip speeds and RPM adjustments may be necessary.
• Cut with a circular saw at 1275 RPM using a 50-70-tooth carbide blade. Expect a feed
rate of 12-16 feet per minute.
• No surface finishing is required. King StarBoard, King StarBoard XL and King StarLite XL
come with a textured matte finish on both sides. King StarBoard AS comes with a
non-skid dot pattern finish on one side and a matte finish on the reverse.
• Edges may be finished with a router. Sanding may be used, but a very fine
sandpaper is required to avoid creating small, hard-to-clean scratches.
• Because King StarBoard sheet products are designed to resist water and grime,
they cannot be painted and the use of adhesives is not recommended. If gluing is
absolutely necessary, products such as 3M’s Scotch-Weld DP-8005 and Lord
Corporation’s 7540-AB have been used with some success. Special welding rods,
designed for use with polymer sheets, are also available.
• Use standard fasteners with oversized holes. Drill pilot holes first, followed by an
oversized hole to allow for expansion and contraction. Use press-in threaded inserts
for applications where repetitive motion is expected, such as a door hinge.
• Mild heat applied with a heat gun will help mold the sheets for curved installations.
Sharper corners must be notched and then heat-shaped.
• Hide fasteners with plugs made from King StarBoard using a standard wood-plug
cutter. Make the plug slightly larger than the hole for a press fit.
Working with King StarBoard .
®
King Plastic Corporation Limit of Warranty is your money refunded or
defective material replaced. All statements, information and data given herein
are believed to be accurate and reliable, but are presented without guarantee,
warranty, or responsibility of any kind, expressed or implied. Statements
or suggestions concerning possible use of our products are made without
representation or warranty that any such use is free of patent infringement
and are not recommendations to infringe any patent. The user should not
assume that all safety measures are indicated, or that other measures may not
be required.
• Store the sheets flat on a level surface, as the
polymer can cold flow.
• Keep away from teak oil and other products that
can stain the finish.
• Use china markers or water-based markers to draw
patterns. Do not use pencil, as it will permanently
mark the material. Pen marks can usually be
removed with household cleaners.
• Provide structural support every 16-18 inches
(typical spacing for 3/4”).
• Keep away from heat sources that exceed 180
degrees F.
• Test applications for unforeseen complications, such
as expansion/contraction issues (note: different
colors react differently to heat). King StarBoard
®
contracts and expands at a rate of 6x10
-5
in./degree F,
changing approximately 1/32 inch for every foot of
length or width over a 40-degree temperature range.
• Use King StarBoard
®
XL or King StarLite
®
XL only
in places where a finished edge is not important.
• Use King StarBoard
®
AS for walking surfaces (or
rout a non-skid pattern into KingStarBoard material).
• Because there is no grain, parts can be cut from any
area of the sheet. Save the scraps for small parts,
shims, spacers and plugs.
• Remnants may be eligible for recycling. Contact
your distributor or King Plastic Corporation for details.
• King StarBoard sheets are made to maintain their
color and finish for the lifetime of the boat. Only
routine cleaning or pressure washing with common
detergents is required.
• Nylon scrub pads and brushes should be used with
care because excessive force can mar the finish.
• For resistant stains, apply bleach and allow it to
soak in.
• Use citrus cleaner, alcohol or mineral spirits to
remove grease or oil stains.
• Automotive silicone spray products or household
furniture polish can help to hide scratches in the
surface. To prevent slipping, do not use these
products on walking surfaces.
Care and Storage
Project Planning
Cleaning and Maintenance
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