heres something i came up with. keeps screws out of the wood anyway.
i laminated more skins on the outside after this pic, but youd just wallow out only the core from the inside and leave the outside skin then glue it in, and put a couple layers over it on the inside.
i just put 2 pieces of pvc down on some wax paper end down, then filled between em with epoxy/cabosil/ and whatever dust came out of the chopsaw.
http://www.classicaquasport.com/phpb...=4582&start=90