Woodworking With Recycled Plastic "Lumber"

[SubChop]

There may be a better thread to discuss this, but I didn't see it and I believe the purists out there probably wouldn't want to discuss the use of recycled plastic lumber in the other "woodworking" threads, even though the tools and techniques are probably similar/identical.

Anyway, the project I have in mind is a set of Adirondack chairs (chairs, two person settee and some footrests) for the back yard. Living in NE, the winters can be a bit harsh on outdoor furniture. The alternatives to working with materials that will withstand the weather seem to be

1. Use some good hardwoods and live with the idea of refinishing them every 1-2 years.

or

2. Giving up valuable garage space in order to store the furniture out of the weather for 4+ months of the year.

With this in mind I stumbled upon some websites that sell recycled plastic "lumber" that is used (from what I know now) just like you would use real lumber. It also comes in a large variety of colors (although I really prefer the look of wood) and is said to be highly resistant to the suns UV rays and of course wouldn't need to be refinished periodically.

Here's one website for example:

http://www.plasticlumberyard.com/

Does anyone have any experience or opinion on this issue?

[Terry Mac]

IMO its a great idea.

I'm really curious as to the differences in working with wood and plastic lumber. Post lots of photos, and let us know what differences you run into.

Thanks, and welcome to the forum!

[Terry Mac]

By the way, I love your signature line! LOL

[thekl0wn]

By the way, I love your signature line! LOL

:D That is a great sig! I've alway said I don't want anyone to question whether I'm dead or not... I want 'em to know for sure! :D

Back on topic... You might also consider your coating options. If you're not object to painted chairs, then there are some incredibly durable coatings out there. Even as far as your stained woods, there are some great automotive/marine grade clears that a durable as heck...

You might also look into the wood you're using. Look into something like Ipe. We did a dock about 13 years ago, and it's NEVER had any sealant on it, and it's still as durable as the day it was built... No buckling, etc. It does "silver" however, but if this isn't a look you like, Linseed oil and other oils can darken it right up.

[SubChop]

Thanks for the welcome.

As soon as I get the plans I'll be able to get a quote for the plastic - shipping may be quite hefty too since I can't seem to find a distributor closer to the greater Boston area than Maryland.

Great suggestion on the Ipe - I've never heard of it but will check it out. I like the silvered look as much as I like the maintenance free aspect of it!;)

[thekl0wn]

One of the other "newer" members on here had a website that had Ipe listed as a type he carried, and it had a picture or two on there of it. Heck, I'm staring at a 2X4X12" piece of it now, but have no way of showing you what it looks like (it's my desk paper weight). A word of warning on the Ipe though... It's fuggin' heavy! Put it this way... The wood won't float! :eek:

[SubChop]

Luckily my local source (Highland Hardwoods) has a website and they list Ipe (or Ironwood) as a type they carry. Now I just need to get my material list together and compare the Ipe to the plastic lumber. I'll keep the group posted.

[Don]

Hey, Guy. Looks like about $5-6 bd. ft. for the plastic lumber from the website. Subchop, you might want to visit your Lowes or Depot and check out the deck lumber. I used some to replace a deck a couple years ago, seems like a 1x6x12 was less than $20 (if I remember correctly) that would put you around $3.33. Of course your colors are going to be limited that way, but it might give you a feel for working with some of the stuff. It drills, cuts and routes like wood, routes even better than wood to me.

You'll have to engineer fasteners at all points, I'm sure gluing anything is out. Shouldn't be a problem with outdoor stuff though, all stainless hardware naturally.

One thing that I have not tried and do not know how it would work is epoxy encapsulation like I used for my boat. If you read up on it you will find that it's much different than simply applying a "finish" on wood. It actually soaks and seals they wood. Most finishes eventually crack and then it's a snowball effect from there. Here is the website for more info on that process. http://bateau2.com/content/view/99/ and index page http://www.bateau.com/

It would be interesting to see a test done with the epoxy just to see what kind of life you could get out of outdoor furniture.

Last time the wife and I were on vacation we came across a place that had plastic furniture. The had a very nice white plastic porch swing, I wish I'd bought it, around $250. But you'd never have to buy another.

That brings up another point. I wonder how comfortable, temperature wise plastic lumber would be to sit on. The material is so dense. Seems to me if it was cold, your butt would not be able to warm it up like wood. A cushion would solve that problem though.

All the best, Don

[SubChop]

Don,

Very good input sir, thank you. As my garage is not truly winterized, I doubt I'll make much true progress until the spring, other than getting the plans, organizing my materials list and deciding upon plastic or Ipe. At this point, from what I've heard so far, it may come down to cost, although the deciding factor for me, the event of a tie, is always real wood if possible and affordable.

Having said that, I do like the idea of using recycled material in an application where beauty is not an overriding factor (I can sit in just about anything that is comfortable out in the yard).

[SubChop]

Well after getting the plans and consolidating the materials lists, I sent out a quote request to the PlasticLumberyard and my local hardwood supplier (for the Ipe).

Plastic lumber delivered would be $1,020
Ipe would be $1,464

So, not a huge difference. Still undecided as to which way I want to go. I like thekl0wn's comment that he's had furniture for 13 years without any sealant on it. I'll have to think about it a bit more.