Allan Morrison wrote:
Can anyone see an advantage using aluminum windowscreen for a layer
or
layers in a composite structure.
The outer layer(s)could be fiberglass where exterior smoothness is
required.
At ~0.5 oz per ft^2 it should be useful for something where high
strength to weight is desired.
Has it been used in some previous design?
Comments please.

I've used this several times to build quick and dirty scoops for wind
tunnel tests of oil coolers. We have a very powerful fan and simulated
airflow equivalents of 230 mph with no degradation of the scoop. I
keep a can of a product we bought several years ago called "Tigerhair"
I think it's made by bondo and usues a standard hardner and catalyst in
a tube...it's mixed like bondo. I used to use window screen but now I
use a stainless mesh with 1/2' grid and .015 dia wire. It's much easier
to form and hold the shape. I only use stainless because we use it on
other stuff and it's available to me, but if aluminum mesh of the same
grid spacing and wire dia. were available it would be perfect. I've
managed to make thin wall sections some as thin as 3/8" using a
combination of tigerhair and bondo, but I see no harm in epoxy gelcoat
for your application, I never trim the excess mesh away because I use
that to form clips to mount the scoop to wind tunnel, but would also
make a good blend skeletin...good luck!