Quote:
lGot a couple ways to make it that I'm pondering.
One would be to make the side templates out of 3/4 inch ply and add 2x3 cross beams then lay and curve 1/4 ply to shape fiberglassing over the out side and coating the inside with epoxy.
Or make the whole top out of 1/4 using a boat construction known as stitch and glue which would be less sturdy but much lighter. Coule be attached with sheet metal screws and the strongest body adhesive I can find. Then for extra security I can add some drip rail clamps that pull everything tight.
I will also need to have racks on top for paddleboards and gear but these could be removed
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Another idea to think about is to make the side templates from 1" or 2" extruded polystryene foam board and the top from 2" foam. Put kerfs in the top so that it will easily conform to the side templates. No ribs or cross braces required.
Then cover the whole thing with fiberglass cloth and epoxy. Do the inside last while it is upside down. Let hardwood blocks into the foam before glassing to be used for your rack attachment points.
The foam would allow you to do a nice radius where the sides meet the top plus it is about R5 per inch.
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