Procell

[paul_z]

I've made a few signs with procell, a decking material (www.procelldeck.com (http://www.procelldeck.com)). I sand the rim joist covers (11 3/4" wide by 1/2" thick) to remove the embossed wood grain and to get a clean, flat surface. Without sanding the edges are slightly thicker than the center.

It carves nicely but has some very small voids. These are easily covered with paint. The paint adheres very well even without a primer.

On a side note, I cemented (welded may be more correct) two pieces together with PVC pipe cement. A can't knock them apart with a 2 pound hammer. This stuff is really tuff.

Any one else use this material?

[jhicks]

Paul I've considered it but glad to see you've done it and like it.
Could you run this stuff through a planer, router or shaper as well to run framing stock?
Wouldn't the embossed grain be a faux wood light sand blast look with the right letter styles?

[paul_z]

Jerry,

I've run the stuff through a thickness planer, a jointer, drum sander, and also routed the edges all with good results. Not knowing what is in the material makes me favor the drum sander over the planer (where the blades could be easily damaged). I have checked the bits that I have used on the shopbot and they seem not to show any wear.

Keeping the wood grain is a problem because the material is slightly thicker at the edges than in the center and it is quite flexible. Without planing or drum sanding, the surface would be lower in the middle and it will further deform under the pressure of a bit. Letters at the edges may look quite different than letters in the center. Anyone have ideas how to get around this? It would be nice to be able to keep the grain for some projects.

Paul Z