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Old 06-06-2008, 02:14 AM   #11 (permalink)
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Originally Posted by bennelson View Post
I like the idea of using foam-core. It is pretty easy to cut into nice shapes, including curves, with a sharp razor knife.

Sometimes it can be had cheap, if you find a place throwing some out with beat-up corners or printing on it.

Sandwiching that in fiberglass sounds pretty easy - just a big sculpture project!

And, for this app. it need not be too strong, so you could use "veil ply" fiberglass from SIG, available at hobby shops. This has the weave and thickness of, say, fine silk, so is very smooth and would adhere to the smooth surface of the foam core board. much reducing the need to sand it. For shaping, kerf cut the back side of the foam board and/or maybe heat it and shape it over a mandrel.

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