White non rotting boat building board. Upvc, expanded PVC, other....

[Moodysailor]

As above Starboard is the go-to marine board for this. Machinable & workable like wood, you just can't bond or seal it very well. Used it for loads of applications when I worked in the US, some of the guys there could do wonders with it. It's available in the UK now, a quick google shows a couple of distributors.

It's not the cheapest stuff though....

 

[rogerthebodger]

As above Starboard is the go-to marine board for this. Machinable & workable like wood, you just can't bond or seal it very well. Used it for loads of applications when I worked in the US, some of the guys there could do wonders with it. It's available in the UK now, a quick google shows a couple of distributors.

It's not the cheapest stuff though....

Any one know what type of plastic Starboard is made from

PVC is easy to bond but HDPC is not

 

[Zing]

I'd look at a glassed over a polyprop honeycomb core like Nidacore or maybe over a structural foam, like most core built boats use now or go with carbon fibre over Hexcel if you want high end. Starboard is a nice product. It is made from HDPE and is pretty dense, at nearly 1.0. That may be a killer attribute. Another option may be ready made honeycomb panels of the kind used in lorry side walls - made by Normanton laminating amongst others.

 

[ortac]

Nidoplast. Also used in aircraft manufacturing

 

[Kelpie]

Nidoplast. Also used in aircraft manufacturing

But needs to be sheathed in glass and resin. I think the OP wanted something trust could just be cut to size and installed.

 

[Hallberg-Rassy]

Are we talking "enclose" (outside), encapsulate (both), or line (inside) here?

How are you treating the corners or edges?

 

[Moodysailor]

Any one know what type of plastic Starboard is made from

PVC is easy to bond but HDPC is not

Sorry, I don't know what material it is made from, but it seems there is an answer in another post. I do know that it resisted bonding from either Sikaflex 292 and 3M 5200, so whatever it is - it is pretty 'slippy'. No issues with mechanical fasteners though.

 

[rogerthebodger]

Sorry, I don't know what material it is made from, but it seems there is an answer in another post. I do know that it resisted bonding from either Sikaflex 292 and 3M 5200, so whatever it is - it is pretty 'slippy'. No issues with mechanical fasteners though.

As another post said its HDPE which I use quite a bit.

The material I get is not a pure white or a smooth surface and as you say resists bonding except with some very special adhesive. It can be welded quite easy as in the manufacture of tanks. I have used HDPE for the floats of my jetty at my condo.