What methods can I use to assemble Maxituf?

An outstanding feature of 100% HDPE plastic lumber is that it can be welded.  Not only to itself but also to other HDPE products including pipe sheet etc.  and the bond will be as strong as the board. This allows you to fabricate just  about anything one can think of. The principle of welding thermoplastics (Maxituf  falls into this category) has been around for quite some time. All you need is a plastic welder and welding rod. Plastic welders come in different levels of sophistication from simple "hot air guns" to fully automated "mini extruders". Welding rods can be bought commercially or can be cut from the plastic lumber. In the latter case color matching is a cinch. Bolts can be used in the same manner as with wood. Screws are extensively used and provide  excellent results, but pre-drilling is a must. Don't try to cut corners here  - you will regret it. To find the correct drill size for this operation, measure  the root diameter of the screw you intend to use, then select a drill with the  same diameter. Square drive screws are preferred over Phillips type. A tiny drop of mineral oil applied to the screw (especially long ones) will greatly reduce friction and your effort. Drill motors equipped with variable speed control work well. For bigger projects consider investing in a screw-gun, it will speed up your work considerably. Plan to counter sink if you like the fruits of your  labor to be pleasing to the eye. Last but not least don't buy cheap drive bits - they will definitely ruin screw heads and your mood. Currently there is no glue available that can assure a bond as strong as Maxituf itself. Various Epoxy glues, contact cement and hot glue can be used to produce  a "moderate" bond. The fact that HDPE is highly resistant to chemicals  and solvents does not make it a good candidate for the gluing process. If you intend  to glue pieces of Maxituf together abrade both surfaces; it will improve the  bond.

 

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