urethane foam core and peel ply on the cheap
I am doing some experiments now. I did a little reading and guessing. Dow super TUFF-R closed cell urethane foam board in 1/" thickness and 4' x 8' sheets is $15 at Home Depot. That and some $4 a linear yard nylon and similar price polyester scrim/fabric were purchased this weekend. I just laid up some test swaths to check adhesion and strength of the peel ply and foam. The foam probably isn't good for much more than non weight bearing hatch covers, or livewells, but the price is right. I should know in 24-48 hrs after the epoxy cures fully. This should at least be good enough for my cover on my console.
For what it is worth, the foam gets a bad rap for structural parts over at boatdesign.net- I suspect rightly so.
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