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#1
June 1st 05, 04:35 AM
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If it were me, I'd use 1/8" plywood or corrugated cardboard as a core.
A few plies of heavy (non aviation, ie, boat type) cloth on the outside, maybe one on the inside. Polyester boat resin (cheap, and not as suseptable to heat softening). Check out the heavier cloths here http://www.discountcomposite.com/glass.html and remember that we're paying about $6 per yard for 9 oz glass for homebuilt airplanes. I like the cardboard idea. Do you think it would hold up to the moisture of the resin? Would I be able to use Bondo to smooth sharp corners? 
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#2
June 1st 05, 04:44 AM
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the resin? Would I be able to use Bondo to smooth sharp corners?
Even better, how about paper mache?
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