We laid up the first 4 foot wide deck panel last week. Here it is with the core in place. I made a mold for the an upside down panel. That way I would have a finished surface on the top. So we laid up 3 layers of the 24 Oz Biax material I have and 1 layer of 1.5 Oz. mat with the cored embedded in the wet mat. Those are 50 Lbs. lead bars on top of it.
A closeup of the core and top skin. If you look closely you can see how well the resin saturated the scrim of the core.
Here is the completed panel before trimming. We laid up 2 layers of 1.5 Oz. mat and 18 Oz. Roving.
When we put it up on the boat it seemed a little too flexible. The laminate schedule is based on a book I have on boat building. I think that when they are all glassed into one it would be stronger. I am working on trying to do a better calculation of the strength. It may be that I have to go with a 2 inch core. This panel will be fine because it has a lateral bulkhead under it with only a 30 inch span or so.
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