Cutting Starboard

[peterb]

Currenty my console setup has a big piece of 1/4" starboard in the middle.

I am thinking of replacing it with either 3/8" or 1/2" starboard.

I would go the thicker route because I have read that it is less prone to cracking. However, isn't it also harder to cut and install flush mounts? Also, what kind of saw & blades am i best off using? I have used a hand jig saw in the past but am thinking that I would be better off with either a spiral saw or a router.

What do the experts out there have to say?

Thanks,

Peter

[FELLOW-SHIP]

Since I am no expert I have used skill saws and jig saws with good blades. I will use a guide to help keep my cuts straight and then I sand. I have also used a straight edge and clamped it to the material flush along the edge I cut and then I used a sander that will remove the high points but the steel straight edge keeps it flat. I have always liked the thought of a table saw and always hated the idea of only using it 2 to 4 times a year and keeping it around all the time. My Dad did that and I can’t tell you how many times a year I would have to move it to get to something else.

FellowShip

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My motto: Just for the Grins

[sponge]

Make a template of what size you want out of 1/4 plywwod.

then take that and two way tape it to your starboard that is cut just a little bigger.
It will give you a sweet edge and exact shape as template.
Make sure you use a router bit with a guide on it.

[EagleOCNJ]

I think starboard cuts very easily with a circular saw or table saw when making long cuts. When cutting with a jig saw or similar, you are right the stuff is hard to cut perfectly probably due to the heat of the slow traveling blade melting the plastic.

[red20]

dixie plastic in ft lauderdlae cuts starboard w/ a router.

[Gary Hill]

In that case why not use a Roto Zip Saw/

[gigolot]

The bad thing about cutting starboard is the plastic shavings go everywhere. I have cut it with a skil saw with no problem, rotozip cuts it well but hard to keep it straight due to the high RPMs, hole saws are a pain because the plastic kinda melts in the teeth.

[Blue197320]

i was cutting my starboard with a battery powered circular saw. worked very good. i also rounded the corners with a jig saw and medium tooth blade. then i sanded it and its smooth. just need a router for all the edges

[Old'sCool]

I just reworked my 23' console with 1/2" Starboard also. I flush mounted electronics and a small storage with recessed clear door. It machines easy, just lay out your lines accurate, measure twice-cut once!!

[peterb]

Very nice layout.

What kind od saw and blade did you use?