Milling/Cutting HDPE Poly Deck - Mountain Buzz

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Old 04-29-2014   #1
Eagle, Colorado
Join Date: Mar 2012
Posts: 50
Milling/Cutting HDPE Poly Deck

Hi all,

I have a piece of HDPE that I need to cut in order to fit it to my frame. Basically all four corners need to be notched and then I need 4 strap holes to hold it to the frame. I also will need to bevel the edges as they are rather sharp. I have never cut this stuff before and hear nightmares about melting, chipping etc. I have a Jig saw, circular saw, router, orbital sander, 4 inch grinder, and a hack saw. Looking for tips, suggestions, do's and don'ts and the like. Thanks in advance for any help!

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Old 04-29-2014   #2
quinoa's Avatar
Ute City, Colorado
Paddling Since: 1999
Join Date: Jul 2009
Posts: 75

I built decks for my frame using 5/8" poly. I made the long cut with a circular saw, short cuts and notches with a jig saw. I then used a 1/4" round with a router to round the edges. For the strap slots I started with 1/4' inch holes drilled a little wider than the desired strap width, ran the jig saw between the holes, then ran the router down the slot to round the edges. I am very pleased with how they turned out and found the material remarkably easy to work with. Good luck
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Old 04-30-2014   #3
Salida, Colorado
Paddling Since: 1986
Join Date: Jun 2012
Posts: 900
Yup, treat it just like wood. No nightmares necessary.

The resulting snow storm is a little messy, so work where it won't get into everything you own AND you can sweep it up easily.
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Old 04-30-2014   #4
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Silt, Colorado
Paddling Since: 2000
Join Date: Jul 2007
Posts: 193
I agree, treat it like wood and do it outside cause it makes a mess!
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Old 04-30-2014   #5
eagle, Idaho
Paddling Since: 2004
Join Date: Oct 2013
Posts: 15
Where can you buy sheets of this stuff? What's a decent price?
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Old 04-30-2014   #6
Join Date: Aug 2006
Posts: 179

Regal - Peidmont inEnglewood, Laird Plastics, SS plastic
it's 4-5 bucks a square foot, worth it, lasts a long time.
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