If you are considering a DIY boat project, chances are that at some point, you will face a critical question: What material is best for your project? In some cases, the answer is obvious, especially when you are simply replacing a broken or worn-out component.
However, when it comes to modern marine plastics and plastic sheets, such as King Starboard (UV-stabilized, high-density polyethylene) and acrylic (sometimes referred to by the brand name Plexiglas), there’s enough crossover to create confusion.
Contents
- 1. The Basics
- 2. Key Characteristics of Acrylic
- 2.1 Aesthetics:
- 2.2 Rigidity:
- 2.3 Ability to Laminate:
- 2.4 Painting:
- 2.5 Transparency:
- 2.6 Heat-Forming:
- 2.7 Finish Options:
- 2.8 Engraving:
- 3. Common Uses for Marine Acrylic
- 4. Marine Acrylic Drawbacks
- 4.1 Brittleness:
- 4.2 Slippage:
- 4.3 Cleaning:
- 4.4 Adhesive Residue Removal:
- 4.5 UV Susceptibility:
- 4.6 Tools and Construction:
- 5. Summary
The Basics
Both Starboard and acrylic are very common materials for marine-related projects, but each offers very distinct benefits and each has specific drawbacks to be aware of. When considering adding a new component or upgrading an existing one, choosing the right material can make or break your project.
This article will focus primarily on acrylic, and will walk through the characteristics, common uses, and some of the drawbacks.
Key Characteristics of Acrylic
Marine acrylic is a rigid and generally glossy material that is commonly used for larger hatches and doors. Its characteristics are about as close to glass or porcelain as plastic can get — thus the trademarked name Plexiglas, which was registered by the German company Röhm & Haas in 1933 shortly after the invention of acrylic by chemist Otto Röhm.
Acrylic offers certain benefits that make it a much better choice for some applications.
Although more difficult to work with than King Starboard, acrylic offers certain benefits that make it a much better choice for some applications. Consider these attributes when determining which material to choose for your project:
Aesthetics:
Acrylic offers a glossy, higher-end look with a sheen similar to that of gelcoat. If your project demands matching the surrounding area, acrylic may be a better bet than King Starboard, particularly for high-visibility areas. Starboard has a lightly textured matte finish and cannot be polished.
Rigidity:
If you are planning on using a marine-grade plastic material for a large hatch or a door, such as a console door, acrylic may be a better choice. These applications often require a long distance between hinges and/or latches, and acrylic’s rigidity will ensure a better seal because it will not flex like King Starboard.
Ability to Laminate:
When a project requires extra strength, acrylic sheets can be glued together to form a stronger, nearly seamless laminate. When weight matters, you can even make the laminate hollow in the middle, providing both strength and lightness. Because adhesives don’t stick to Starboard, it cannot be laminated to add strength
Acrylic has a higher-end, glossy finish with a sheen similar to gelcoat, making it a good choice for access doors in high-visibility areas.
For larger access doors with irregular shapes that limit hinge positions — like this Key West console door — acrylic’s rigidity makes it a better choice than Starboard.
Painting:
While acrylic comes in many different colors (and levels of translucency), getting exactly the color you need may prove difficult. Unlike Starboard, though, acrylic can be painted, allowing for a perfect match to the surrounding area.
Transparency:
When it comes to livewell lids, windows, windshields, electronics box doors, vent hatches and escape hatches, transparent or translucent acrylic is hard to beat. Lighter weight than glass and more forgiving, acrylic is the most common material used for applications that require transparency. Starboard is available only in opaque colors.
Heat-Forming:
For applications that need to follow the curves of your boat acrylic is a better choice than Starboard. While acrylic is not flexible, it can be heated and bent, holding the new shape for its lifetime. Conversely, while Starboard is more flexible, heat forming it is not recommended. Bending Starboard is difficult, and the material can turn brown with too much heat. Even when it is successfully bent, it is weakened and can crack with time.
While Starboard is more flexible, heat forming it is not recommended.
Finish Options:
While acrylic is often seen with a glossy finish, other finishes are available. In its transparent forms, it can be clear, tinted, frosted, and even green-edged to mimic glass. In its opaque forms, acrylic is available in various colors.
Engraving:
For applications that require logos, labels or any sort of printing, transparent and translucent acrylic makes for an excellent engraving surface. Laser- or machine-engraved acrylic offers a high-end look for your project that will last its lifetime. Starboard can be engraved by machining, but special ColorCore Starboard — which has a contrasting layer in the middle — is required.
In applications where translucency or transparency is needed, acrylic is a near ideal material.
Translucent acrylic is available in clear, a variety of tint levels and tones.
Transparent/translucent acrylic engraves beautifully with either a laser or CNC machine.
Common Uses for Marine Acrylic
While there is some crossover on projects that use either acrylic or Starboard, there are certain projects where acrylic’s characteristics make it a more suitable material. Here are some of the most common projects that either require acrylic or are greatly enhanced by its use:
- Windows and portholes
- Windshields
- (Clear) livewell lids
- Larger console doors
- Switch panels and dash panels
- Higher end push pole holders and cup holders
- Escape and vent hatches
- Doors that require a more secure seal
Marine Acrylic Drawbacks
While acrylic offers many benefits and may be the right choice for your project, there are a few drawbacks you should be aware of:
Brittleness:
While acrylic offers better rigidity than Starboard, it comes with a price. Acrylic is more brittle and can break if too much pressure is applied to it. This is particularly important to keep in mind in applications where the acrylic may be stepped on or where excessive and/or uneven force might be applied to it. If it breaks, the fracture can be sharp enough to represent a safety concern.
Slippage:
While Acrylic is a great material for some hatch applications, it may not be the right choice for hatches that will be stepped on. Because of its glossy finish, the surface can become very slick when wet and represent a safety issue on your boat.
Cleaning:
Acrylic is easy to clean, but can be damaged by certain cleaners, particularly ammonia-based cleaners and abrasives. Crazing and scratching caused by improper care can ruin the high-end look that acrylic offers.
Adhesive Residue Removal:
Acrylic makes a great surface for decals, stickers and tape, but removing the sticky residue from these adhesives can be extremely challenging.
UV Susceptibility:
Prolonged exposure to UV rays can make acrylic brittle, and in transparent or translucent applications, lead to “crazing”. By design, most boats are made for sunshine, but proper care needs to be considered for acrylic components. Full boat covers, or at least console covers, can dramatically extend the life of acrylic windshields, doors and hatch lids.
Proper care needs to be considered for acrylic components.
Tools and Construction:
Unlike Starboard, acrylic can be hard to work with. Prone to chipping, acrylic fabrication requires special tools and more care to get the right result. Any acrylic edge will need to be polished after cutting. If you need an acrylic part for your project, but are not comfortable shaping or drilling it yourself, Boat Outfitters can provide a ready-made solution for you through the “Custom” link on our website.
Prolonged UV exposure or cleaning with ammonia-based products can cause crazing in acrylic over time.
Unlike Starboard, acrylic can be difficult to work with and requires specialized tools, like these drill bits.
Summary
When it comes to harsh marine environments, the durability and wide application range of both acrylic and Starboard can meet most DIY project demands. Understanding the benefits, limitations and characteristics of each can help you decide which one is right for you.
If you are looking for a material that offers a rigid, high-end or even transparent solution, acrylic may be a better choice than Starboard. Going into your project with a clear understanding of the limitations and drawbacks of acrylic can ensure that whatever you are designing will meet your needs for many years to come.