Quote:
Originally Posted by Crazyrabbit
The most beautiful soapbox derby car I ever saw was fiberglass over expanded metal. Shape the expanded metal to the desired shape drape the fiberglass satin weave over it and saturate it with polyester or epoxy resin. Let that cure and add closed cell styrene foam (Like the Dow blue foam insulation) or balsa wood cores and add a layer to the inside. Aluminum or fiberglass window screen would work too. A downside to using foam for cores is you have to use epoxy with it and that is more expensive. 0.007" thick aluminum newspaper lithography press plate is another material to consider for 2D sections.
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And you can use a skim coat of TiteBond glue over styrene foam before the use of polyester resins.