Your Opinion on Material

[jrmccoy]

So really doing some heavy body work on Maggie Mae including the midship and aft deck doors. They are all original Hatteras which started off teak and got painted over the years. In any case the aft deck panels are bad and I have removed them. They fit into the 3/4” channel along with a 1/2” piece of quarter round leaving 1/4” for a panel. My plan is to beef up the panel and go with 1/2” material and route out a channel to accommodate the 1/2” trim for a flush fit. Question: The panel will be filled and painted in any case. Would you use Starboard or 1/2” marine grade plywood and which brand? I’m leaning starboard but a little worried about the flex for a panel in the 20” x 30” range. Do you think 1/2” Starboard would be rigid enough for a panel 20” x 30”?

 

[Pascal]

Even 1/4” starboard will be rigid enough but starboard can not be painted. If the color matches the paint, fine other wise you ll be better off with painted plywood. Why go to 1/2”? Stick with 1/4” ply and just keep the wu
Quarter round as this will preserve the panel look matching other doors

 

[jrmccoy]

Thank you for this info. I have actually painted some starboard successfully before...are you sure its not spec'ed to be painted? I'd really love to go with 1/4" plywood as that would fit as to original specs. Do you think 1/4" plywood would be rigid enough for a panel that size? 20 x 30 approximate.

 

[Pascal]

I m pretty sure it s in the specs. Maybe some paints stick to it but many glues and epoxy don’t stick well to it either

I m pretty sure the original ply is 1/4”, isn’t it? It supported all around so it will be fine

 

[Cricket]

Are you sure it was Starboard that was painted and not some sort of PVC material?
Btw, for the panel replacement I would use Okoume or Meranti plywood and coat it out with epoxy and also at least fair and prime it before installation.
Or, G10 also would be a good replacement, but only 1/4" because 1/2" would be too heavy.
Or, we've been using some pre-laminated cored panels for some of our projects from Carbon Core.
https://www.carbon-core.com/product-category/laminated-panels/

 

[dottieshusband]

I've considered replacing the lower panel in my PH doors with 1/4 PPG Solexia Green laminated glass, set in a polyurethane glue... would withstand the weather better, and certainly stronger than the current 1/4 plywood, better visibility, and no need to paint!

 

[SKYCHENEY]

Nothing sticks to Starboard. I have replaced with plywood. Then epoxy coated and painted. It will last for many, many years. Don't try to re-engineer it. It lasted for 30+ years the first time. With the epoxy coat on the new ply, it will outlast that.

 

[Glory]

I gave used PVC to replace the panels that look like the support for the bridge, it's not, completing the wing doors wall. Worked out well. Glory is bright white and the color is close. It is my understanding PVC can be painted with a bunch of paint products.

 

[Captain Ralph]

I have often thought about shower or kitchen fiberglass panels.
https://www.lowes.com/pd/48-in-x-8-ft-Smooth-White-Wall-Panel/3446544
Less than 1/10" thick, two can be used smooth side out and painted.


Also, Bertram, BlackFin and others used Formica to cover panels. I can show off some 25 year old exterior Formica panels still in good shape and holding color.

 

[dsharp]

If you are going to paint the panels try to source some MDO. It’s used for outdoor signs and holds paint really well.