Frequently Asked Questions


KERFKORE

TIMBERFLEX

FLEXBOARD

GERERAL PRODUCT QUESTIONS


KERFKORE

Q: What is Kerfkore?

A: Kerfkore is a stable substrate that has been kerfed into small rib sections that are joined together with a very flexible latex impregnated paper. This allows for the attachment of high pressure laminates, veneers, metals and other semi-rigid materials laminated flat and then formed into virtually any shape.

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Q: How do I use Kerfkore?

A: Kerfkore is designed to be laminated flat and then formed into shape. It is best to size the Kerfkore to the finished dimensions and then apply the face material. The face material can then be easily trimmed with a router to match the finished size.

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Q: How do I attach the face material to Kerfkore?

A: Two attachment methods are preferred. First the use of a contact adhesive of either water based or solvent based is most desirable due the flexibility of these adhesives. The Kerfkore should be positioned on a flat surface with the black paper face side up. The black paper should be cleaned to remove any foreign material. The Kerfkore along with the face is now ready to be sprayed or brushed with the contact adhesive. After allowing the recommended drying time, the Kerfkore will need to be on a flat smooth surface and the face positioned correctly for attachment. The use of a J-roller with moderate pressure is recommended to firmly attach these two materials together. Second, the use of PVA glue is acceptable to attach your face to the Kerfkore. Preparation of the Kerfkore should be as stated above. We recommend a standard PVA glue (not a cross linking type) be applied to the Kerfkore's black paper face. The face material can be applied to the Kerfkore by a couple of methods. A vacuum press or a cold press is preferred. If using a cold press we recommend a maximum of 30PSI be used. Pressing at a higher pressure may result in the compression of the black latex face and may cause the product to telegraph. After allowing the recommended drying time, the assembly can be trimmed and used. It always best to test the glue you plan to use to ensure compatibility for your process.

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Q: What face material is recommended to use on Kerfkore?

A: Kerfkore is designed to be used with a High Pressure Laminate, phenolic backed veneer, two-ply veneer, metals and other similar bendable materials.

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Q: Do I need to use any particular type or brand of HPL?

A: Most brands are acceptable. A vertical grade of HPL is preferred, as it will allow for more flexibility and is therefore more desirable in most applications. A horizontal grade HPL will also work provided it will give the flexibility needed for the particular application. It is always recommended that a test be made with a small sample to determine the usability of the selected HPL.

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Q: Can I use a paper backed veneer on Kerfkore?

A: No. A paper-backed veneer is not recommended for use on Kerfkore. The black paper face on Kerfkore is designed to be very flexible. A paper backed veneer will not provide the rigidity needed to keep the face from telegraphing. A phenolic backed veneer or a two-ply veneer is acceptable for use with Kerfkore. The two-ply veneer should be the type with a perpendicular backer as opposed to a parallel backer.

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Q: Can I get a sheet of Kerfkore that is 8' wide and 4' tall?

A: No. Kerfkore is only available in 4' wide and 8' tall. The reason it is not available in an 8' width is because the easy splicing method. When using Kerfkore your face material is designed to be the splicing material. When an 8' wide section is needed you just cut the 8' long material into two 4' wide sections. These sections are then placed side by side with a small gap between the sections to duplicate the normal kerf width. The face material is then laminated to the two pieces of Kerfkore and you have now easily produced a product that is 8' wide and 4' tall.

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Q: How do I attach Kerfkore to a framework?

A: Since the Kerfkore product is laminated flat, it is possible to cut grooves or dados in the product to allow it to fit over or against forming ribs. These grooves and ribs can then be attached with the use of glues and pins where possible. The use of PVA glue is suggested where these parts meet with the use of a hot melt glue to help secure the parts until the PVA glue can cure. Also Kerfkore can be clamped into place and glued together with of without the need for grooves or dados.

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Q: What type of framework do I need to use?

A: There are numerous methods to accomplish this. We recommend the use of a framework with horizontal ribs being used to form the Kerfkore product. These ribs should be as uniform a possible thus allowing the Kerfkore to smoothly bend into the desired curve. Verticals ribs are only required to position the horizontal ribs or provide a vertical seaming rib.

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Q: Why can I not attach the Kerfkore to my framework and then apply my face?

A: Kerfkore is designed by using the black latex impregnated paper to provide the flexibility that prevents telegraphing. When the face material is attached prior to forming, it allows for the uniform bending of the assembled product without telegraphing. If Kerfkore is installed first, the black flexible paper does not have the ability to uniform the ribs and telegraphing can occur due to uneven attachment of the ribs.

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Q: What is the difference between Regular Kerfkore and single sided Kerfkore?

A: The two products have the same characteristics. The Regular Kerfkore has a back composed of a phenolic impregnated sheet. This enables the product to be handled as a semi-rigid sheet. The use of a scoring tool will remove the backing paper to allow the product to be as flexible as single sided Kerfkore. This can allow you have a flexible panel where needed and a rigid section when preferred.

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Q: Is the particleboard substrate the only core available with Kerfkore?

A: No. Kerfkore is also available with a MDF or plywood core. An optional fire treating of the core is also available.

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Q: How tight can I bend Kerfkore?

A: Kerfkore will bend to a 3-1/2" radius. This does depend upon the face material and its flexibility. Kerfkore will bend to a smaller radius providing the face material will allow it.

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Q: Can I make curved doors out of Kerfkore?

A: Kerfkore is very suitable for curved doors as its flexibility provides minimal resistance or spring back and is formed by the material being used for the face and back. Please see our Technical Information manual for more details.

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TIMBERFLEX

Q: What is Timberflex?

A: Timberflex is a flexible product designed for use in numerous kinds of radius projects. It consists of a core of kerfed particleboard with a 1/8" thick three-ply Italian poplar plywood face.

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Q: How do I use Timberflex?

A: Timberflex is designed to be attached to the framework first before applying face material. Timberflex is designed to be installed using conventional fabrication methods as an alternate to bending plywood.

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Q: How do I attach Timberflex to a framework?

A: Timberflex should be cut to match the framework. Then the use of PVA glue and staples are preferred to attach the Timberflex to the framework. If accessible the use of a hot melt adhesive is also recommended to help secure the parts until the PVA glue can cure.

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Q: How do I attach the face material?

A: The use of a suitable contact adhesive is most frequently the method used.

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Q: How do I splice Timberflex?

A: Timberflex can be spliced on either a horizontal or vertical rib. Because the panels are dimensionally calibrated to have a uniform thickness from sheet to sheet, it requires minimal joint preparation before the face material can be applied.

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Q: Why do you recommend using horizontal ribs in place of vertical ribs with Timberflex?

A: Timberflex will form a uniform radius by forming around only horizontal ribs. The use of vertical ribs, if not set back from the horizontal ribs, can distort the uniformity of the radius. The use of a vertical rib is only necessary when making a vertical seam.

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Q: What face material can I use on Timberflex?

A: Almost any face material can be used on Timberflex after it has been formed into the desired shape. HPL, phenolic-backed veneer, two-ply veneer. Three-ply veneer, paper-backed veneer, metal, and numerous other semi-rigid materials. The Timberflex face can also be stained or painted when desired.

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Q: What radius can I make with Timberflex?

A: The recommended bending radius for Timberflex is 5". While a smaller radius may be obtainable, it is best to test before attempting a radius under 5".

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Q: What sizes are available with Timberflex?

A: Timberflex is available in a nominal 4 x 8 and 8 x 4 sizes and in and thickness.

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Q: What substrates are available in Timberflex?

A: Timberflex is standard with a particleboard core. Plywood, MDF and a fire rated particleboard core are available.

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FLEXBOARD

Q: What is Flexboard?

A: Flexboard is a flexible product designed for use in numerous kinds of radius projects. It consists of a core of kerfed particleboard with a .080 hardboard face.

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Q: How do I use Flexboard?

A: Flexboard is designed to be attached to the framework first before applying a face material. Flexboard is designed to be installed using conventional fabrication methods.

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Q: How do I attach Flexboard to a framework?

A: Flexboard should be cut to match the framework. The use of PVA glue and staples are preferred to attach the Flexboard to the framework. If assessable the use of a hot melt adhesive is also recommended to help secure the parts until the PVA glue can cure.

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Q: How do I attach a face material to Flexboard?

A: The use of a suitable contact adhesive is most frequently the method used.

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Q: Can I press a single ply veneer to Flexboard?

A: Yes. A single ply veneer can be attached to the Flexboard before forming. We recommend a cold press application with a pressure of at least 125psi. After a single ply face is applied, a bending radius of 16" may be obtainable.

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Q: The hardboard face on Flexboard looks too slick to attach a face to. Is a particular glue recommended?

A: The hardboard face is not an oil-based board as with some products. Contact adhesives and PVA glues are both very compatible with the hardboard face.

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Q: How do I splice Flexboard?

A: Flexboard can be spliced on either a horizontal or vertical rib. Because the panels are dimensionally calibrated to have a uniform thickness from sheet to sheet, it requires minimal joint preparation before the face material can be applied.

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Q: Why do you recommend using horizontal ribs in place of vertical ribs with Flexboard?

A: Flexboard will result in a uniform radius by forming around only horizontal ribs. The use of vertical ribs, if not set back from the horizontal ribs, can distort the uniformity of the radius. The use of a vertical rib is only necessary when making a vertical seam.

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Q: What face material can I use on Flexboard?

A: Almost any face material can be used on Flexboard after it has been formed into the desired shape. HPL, phenolic-backed veneer, two-ply veneer, Three-ply veneer, paper-backed veneer, metal, and numerous other semi-rigid materials. The Flexboard face can also be painted when desired.

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Q: What radius can I make with Flexboard?

A: The recommended bending radius for Flexboard is 10". While a smaller radius may be obtainable, it is best to test before attempting a radius under 10".

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Q: What sizes are available with Flexboard?

A: Flexboard is available in a nominal 4 x 8 and 8 x 4 sizes and in and thickness.

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Q: What substrates are available in Flexboard?

A: Flexboard is standard with a particleboard core. Plywood, MDF and a fire rated particleboard core are available.

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GERERAL PRODUCT QUESTIONS

Q: What is the difference between Timberflex and Flexboard?

A: The two products are very similar and can both be used in the same methods. The biggest difference is the face material. Timberflex has a 1/8" three-ply Italian poplar plywood face where the Flexboard has a .080 hardboard face. Both face products have advantages over bending plywood products.

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Q: Why should I use Timberflex or Flexboard in place of bending plywood?

A: Both Timberflex and Flexboard are dimensionally sized to have uniform thickness whereas bending plywood varies in thickness. Our products are free of odors. The face material on both Timberflex and Flexboard require no preparation before applying your face material. Only one layer of Timberflex or Flexboard is required to give you a durable quality product.

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Q: What is the difference between 4x8 and 8x4?

A: The difference between 4x8 and 8x4 is the direction in which the board will bend. When bent a 4x8 will stand 8' tall and wrap like a column. The 8x4 panel size will stand 4' tall and wrap like a barrel. The second number also designates the direction of the grooves. On a 4x8 the grooves run the 8' length and on a 8x4 they run the 4' length.

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Q: Can you use these products to make doors and columns?

A: Yes, all of the products can be used to make doors or columns depending on your radius and project need. Please consult our technical manuals for step-by-step procedures for door fabrication or contact our engineering consultants at 800-637-3539.

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Q: Where can I purchase your products and how much do they cost?

A: Our products are available through an extensive North American distributorship program. Please consult our Distributor Network to find a Distributor in your area. The distributor will provide pricing and availability. If there is not a distributor available or you have questions regarding the product, please check with our Customer Service Representative at: 1-800-637-3539.

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“I used Timberflex to design a hostess stand, tables, and booths in the Casitoga restaurant. This stuff is genius, you can't beat it. It is really amazing and the designs you can create with this stuff are unbelievable. We keep it in inventory at US Millwork and use it every time we have a radius project. It really works wonders.”
Rick Selvage, US Millwork, Inc.