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  Topic Review (Newest First)
04-04-2012 06:48 PM
Re: Homemade navigation housing

We recently mad a chart plotter mount with inch Starboard and it works quite well so far. Of course it is brand new so no telling It is attached with some hose\cable clamps that we removed the rubber from, 7/8 I think. We cut it with a Japanese hand saw and jig saw for the corners then sanded it.
Could be a bit nicer but this works for now.

04-02-2012 06:56 PM
Re: Homemade navigation housing

I am pondering this myself as i do not want to spend the money on a navpod right now and the idea of a foam block that could be eaten by acetone AKA a lost foam mold seems interesting

On the other hand After spending the time to make the hatch riser out of wood i kind of wish a could have bought one for 2 or 3 hundred as it came out great BUT cost a huge amount of TIME
04-02-2012 06:05 PM
Re: Homemade navigation housing

How about this for Plan B?
Last year a friend built one using foam and fibreglass.
He built a block out of foam - building insulation - pink or blue.
Cut it and glued it so that it would fit over the pedestal guard - with some room to spare.
Then he hollowed out the space for his instruments - bread knife and hot knife.
Then he glassed and painted the whole deal.
Sorry that I don't have pictures but you get the idea.
Since you are local, I could arrange a look-see.
04-02-2012 10:35 AM
Re: Homemade navigation housing

Originally Posted by Faster View Post
I made our table our of 1/2" material and would upgrade that next time.. it's too flexible and without stiffeners will bend and not hold its shape.
That's interesting to know, I would have thought the 1/2 inch would have been sufficient for a table. Maybe back to the plan of making my table from mahogany.
04-02-2012 10:06 AM
Re: Homemade navigation housing

Originally Posted by Ritchard View Post
I just did a bit more reading,..... I'd be interested to know what you find out.
As would I... btw I made our table our of 1/2" material and would upgrade that next time.. it's too flexible and without stiffeners will bend and not hold its shape. I've added stiffeners beneath the table and its "OK" but not as stiff or stable as I envisioned. Friends have a 3/4" thick table that is much more solid feeling.. 5/8" might be a compromise if available.

As to table saw cutting, I didn't have a joinery blade so that may be part of the issue.. the sawn edges were quite rough looking. whereas the routered edges came out beautifully.

For fastening I used SS screws.. you could probably sink and plug them as you would a teak table if you wanted to. But it will be very interesting to hear how any attempts at gluing this 'slippery stuff' goes! Keep us posted...
04-02-2012 09:01 AM
Re: Homemade navigation housing

I just did a bit more reading, it seems it can be glued, using Scotchweld DP-8005 or Lord Corporation's 7540-AB. A quick survey of Starboard glueing posts seems to indicate that it's difficult. Some say impossible, but those are the guys that I tend to like to prove wrong.

Maybe it's worth finding some scraps to test with before you begin to design/engineer your box?

I have heard of scuffing the material with some heavy sandpaper, and as well of hitting it lightly with a torch to sort of "open up" the edges. I'd be interested to know what you find out.
04-02-2012 08:25 AM
Re: Homemade navigation housing

I would be using 1/2" board, rabbet the corners, use a strong glue bond and temp fasten with stainless steel screws (recess). Has to be secure and somewhat watertight. I never worked with the material before and if it does not take a strong glue bond then it most likely will not work as I don't want the look of all the screws and I will need to round all the corners. A simple box is becoming more complicated.
04-01-2012 10:47 PM
Re: Homemade navigation housing

I've used a bit of Starboard lately. I used it to make a panel to cover the holes left by the stone-age Datamarine instruments (no time this spring to glass and paint), as well as using it to make a new face for a used eBay Navpod. It's a really nice material to work with - other than getting white plastic sawdust all over my basement workshop. I respectfully disagree with Faster with respect to cutting. I found that it cut beautifully with a table saw, leaving very clean edges. It sure takes forming with a router nicely.

If you were making a box shape, how would you fasten it together to get a nice result? The material is very hard to fasten to itself, it doesn't really take glue or anything. I understand you can either Ultrasonic or RF (Can't remember which) weld it, but otherwise, how do you make a nice box - esp with the likely 1/4 inch stock?

I may buy a chunk of 1/2 inch to make a cockpit table now. I really like the way it comes out after rounding edges and such.
04-01-2012 10:37 PM
Re: Homemade navigation housing

As it happens I tried using a holesaw on a piece of StarBoard last night.. it works but the material just as soon melts than cuts this way. Clearing the blade frequently is mandatory. This too would probably get better results using a template/guide and a router bit.
04-01-2012 03:49 PM
Re: Homemade navigation housing

As long as the material is workable and will last, I should be able to make it work and look nice. Attaching to the guard is not too much of an issue, I can use surface mounted stainless steel tube clamps.
I really do like the Navpods but I have already spent way over my project budget this year on a new feathering prop, Simrad nav station and a expensive bottom barrier coats & paint project.
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