Weather proof Melamine?

[davidallen]

does anyone know of a coated material like Melamine that will stand up to weather and use?

I'm designing a 'kitchen box' to take camping and looking for an alternative to plywood with laminate applied to both sides.

tia

[billp]

David,
Why not just laminate Melamine to Extira?

[ron brown]

There was a product called "Fin-Form" or "Ply-Form" that was a plastic coated plywood I could get years ago when I was building conrete forms for bridges and such. Thanks for the nightmare.

Ron

[davidallen]

Bill,
I could laminate myself, but I don't have space to layout a 4X8 panel. (It's crowded with 1 person in it) Plus, the best I could do is almost as good as commercially applied laminate.

I'll probably build from standard ply then overlay with laminate. It'll just take extra time.

[stickman]

Why don't you use marine grade plywood or paint extira?

[gene_marshall]

David,
some plywood suppliers will lay this stuff up for ya.( for a small fee of course.)

I would call a few local suppliers and ask some questions.
Gene

[davidallen]

Jay,
The box is going to be bounced around the back of a pickup so it needs to be rugged. it's also going to be used to prepare food so it needs to be easily cleaned.

Gene,
Thanks, I'll call around.

[rookie432]

David,
I would consider making the whole thing out of a heavy duty plastic sheeting product. You can buy pvc,hdpe and other products in 1/4"-1" thick sheets. Check out www.plasteak.com (http://www.plasteak.com). They supply materials for similar use in boat industry.
Hope this helps.
Bill

[bleeth]

David: You can use space, table saw, etc. at my shop anytime you want. In general I would probably put solid wood outside corners either around that kind of box or inset laminated panels into solid framework to protect the fragile laminate edges. I've built tons of deck boxes, etc. that way.

Dave

PS: I keep a spray pot full of contact cement at all times for fast laminating.

[davidallen]

Bill,
I thought about using 3/4 Starboard, but that's too heavy. How well does 1/4" stand up to structural stress?

On a related note, how do you join Starboard or similar stuff face to face? I want to put 2 pieces of 3/4" together to make a 1 1/2" thick slab then machine through the joint so it should be seamless.

[davidallen]

Dave,
Thanks for the offer, I may take you up on it.

I thought about frame and panel using 2X2 frames and 1/4" panels but wasn't sure about installing internal structures like shelves, dividers, and drawers..

[bleeth]

Once you have a layout interior construction of partitions and drawer glides is done just like traditional frame and panel furniture: crossmembers attached to the carcasses framework.

[gene_marshall]

BTW,
I made my camping box out of western red cedar.
Lightweight and sturdy.not to mention rotproof.

i would have used corian for the top, but wound up with a cutting board instead.

Have fun camping...nothing like the great outdoors.
Gene

[davidallen]

Gene

I may lay up some panels of cedar and do the same thing. I could laminate the horizontal surfaces for easy cleanup

da

[gene_marshall]

Here is a sad note, but very important.

When I first made the box.
My intention was to put the camp stove on top.
the first trip, I was boiling water for corn. standing right there with the thing.
one of my freinds kids came over and leaned on the box causing it to shake and the corn water fell to the ground.

The child got hit by the splash of boiling water, mostly on his legs. 2nd degree burns and a trip to the hospital.

I still get sick to my stomach thinking of this.

The kids as big as an ox nox, I still see his family from time to time, they harbor no ill will.
But I wind up apologizing anyway.

My point in writing this is... I was so proud of the box up till that moment, and after I wanted to smash it into a million peices.

Please take note the camp stove must be secure.

At the time we had a camper with our group who worked for an insurance co. doing risk assessment and management.
He was standing a few feet away when this happened and said that no one could have seen it coming.
sometimes safety is not only proper planning but also thinking beyond the usual parameters.

I still feel sick over this.
Gene