prepping for flexiteek and floating cockpit core recommendations

So, I want to use some flexiteek in my boat build, but flexiteek installed is $70 / sq. ft. My cockpit is about 8x13, so going full flexiteek would cost around 7 grand. Not worth it, if you ask me. The other issue is I want my surface scrubbable for fishing, so some kiwigrip deck is planned.

But I still like flexiteek, so I wanted to use some flexiteek and make a pathway of it from the boarding area to the cabin door, and perhaps some inside the cabin if the wife wants it.

So, the reason this is in the builder forum..

Flexiteek installed is 1/4" thick. If I wanted to build my cockpit more inexpensively than a full cover of flexiteek, I could use 12mm corecell on the bottom and add 1/4" double sandwich (club?) and leave a step for the install of the flexiteek. To make it more complicated, part of the cockpit is on the hulls and part of the cockpit is floating since it is a catamaran and demountable.

Is this as straightforward as just laminating the 1/2" deck and then laminating 1/4" corecell to the face of the other laminate? Would you do it in steps to avoid airpockets, or full on wet on wet in one shot?

Or am I way off and should I be routing out 3/4" material for where I want the teak and laminating all of it in a single sandwich?

And as long as I'm asking, what core product would have the least flex? There are two 4x8 panels that will be floating; they will be joined on the 8' side with aluminum angle brackets. I might need to put some stringers under them for flex, but wondering about the best core material as well.

I will be asking the designer, but wanted to ask here as well. Thanks.

 

I would just laminate the cores together and vacuum bag some glass over them. You should still put a slight radius on the 1/4 edge but wouldn't need much and you can fill that later with the same caulk you use between the flexiteak panels.

 

Jorge - do you like walking on 4x8 12mm with two layers of glass each side, or is it weak underfoot and does it flex too much? Would you add some foam stringers and laminate them in on on the bottom and glass over the entire thing, or glass it and then laminate and glass the stringers above or both and upside down on the vac table to avoid fairing the underside of the cockpit?

 

4 x 8 clear span? That is too much, I have 31" span with 3 layers of 12 oz (+-45 and 0-90) and it's perfect, I have had 11 people on my boat and nothing feels soft. If you are going to vacuum infuse I would lay the foam stringers on top of the panel laminate, lay more glass on top of those and shoot it all in one shot. If you aren't infusing, just tape or glue them in later but much easier to just infuse it all in one shot.

 

Yes, 4x8 clear span and another 4x8 clearspan next to the other one with two aluminum angles on the 8' sides. The boat has a big cockpit. No infusion, just vacuum. Thanks Jorge.