Quote:
What happened was I would get small air voids no matter how hard I tried to evenly squeeze the pieces together. Then I cut a grid pattern 3/4 the way through the material to make it shape better. If I were to do it again I would consider the grid or squares. With the squares you are more likely to get the air out and form better to the shape of your skin (like tiling).
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Exactly why the core is cut into squares! One of my first jobs at Sea Vee Boats back in early 80s was to reduce 4x8 sheets of 3/4" ply to 5" squares on the table saw.
