Lou wrote:
Ok, I've made a few pieces to try out using 1/4" foam and fiberglass on
both sides. When I cut the pieces to shape with my band saw, small
strips (1/4" or so) seem to want to seperate. Is this common or did I
mix the epoxy wrong? The big parts are staying together, the fiberglass
itself is staying to gether but the small parts are seperating from the
foam.

Lou

I have made a substantial number of parts using 1/4 inch foam as the
core material and have never experienced any problems with peeling. I
have cut the parts with a band saw as well as the dremel and never had
any problems with separation.

I believe the key issue is use of the right foam core material and
preparation. The foam must contain openings for the microepoxy to
penetrate. I spread on the microepoxy mix and pressed it into the foam
followed by the wet glass. That was covered by pealply and where
possible a layer of plastic and weight. So far, I have never had any
problems with this method.