Replies

1. 
   JohnWW | May 24, 2010 10:52pm | #1

   A Google search doesn't turn up any composite board called Everboard, are you thinking of EverGrain, a decking material?

   If it is EverGrain, it is a mix of sawdust and recycled plastic and will probably handle much like solid polyethylene.  I doubt if it will drill and cut at all like solid wood.  It is probably best cut with an end mill in a milling machine or a horizontal mortiser, but the cutter geometry and the bit speed will probably be different from those used for wood.

2. 
   SawdustSteve | May 25, 2010 09:09pm | #2

   Mortise

   If you're talking about composite (mostly plastic) decking, AND making a through mortise, then drill a hole to remove most of the 'meat' and then use a good jigsaw to square up the corners.  Blind mortise work is another question completely.  it really does not have the solid structure needed for fine woodworking' as it will expand and contract with the change in temperature.

   If you're talking about Azek, wonderboard or Starboard, then the same info holds true, only you will be covered with little white flakes that give a new meaning to static kling

       SawdustSteve    Long Island, NY   (E of NYC)

3. 
   Scrit | Jul 06, 2010 02:19pm | #3

   I've had success in the past on composite recycled polyethylene decking materials using a square chisel mortiser, however carbon steel tooling doesn't last long on the material and it's a bit hard on the motor, so you really need big industrially rated kit to do this sort of thing. My own experience is that square holes in plastic composites seem to be a good place for stress fractures to start, so in the end we went over to drilling and using s/steel coach bolts and coach screws with backing cleats (1-1/2in square section) - drilled with conventional power augers. Not elegant, but simpler and durable.