Inexpensive, Lightweight Core for Interior Uses?

Discussion in 'Materials' started by CatBuilder, Mar 18, 2011.

  1. CatBuilder

    CatBuilder Previous Member

    What would you use as a core material or building material to build an interior out of if you wanted...

    *lightest weight
    *economical
    *will last as long as the boat


    The material would be for non-structural items like settees, cabinetry, cabin sole, tables, counters, etc...
     
  2. PAR
    Joined: Nov 2003
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    PAR Yacht Designer/Builder

    Why use a core under those requirements?
     
  3. michael pierzga
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    michael pierzga Senior Member

  4. CatBuilder

    CatBuilder Previous Member

    Yes, why indeed?

    How would you build the lightest interior?

    Thanks for the links, Michael.

     
  5. michael pierzga
    Joined: Dec 2008
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    michael pierzga Senior Member

    And go crazy saving weight on interior components. It makes a huge difference. The boat Im sailing now is one hudred percent cored panel interior. You might be wise to checkout a furniture building website blog like fine woodworking or something for tips and tricks when working with light panels...hinges, backing plates , mollies....and veneer tricks. If possible visit a lightweight modern boat like a Wally with your camera and record details.
     
  6. AndrewK
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    AndrewK Senior Member

    Catbuilder; if you want lightweight and economical then light weight plywood is your best choice. Locally I can get a 12mm, 10.5kg sheet of balsa ply for $60. This is made from 3 thick veneers of long grain balsa with thin hardwood faces. This is definitely for non structural work, there are also other plywoods 13 - 15kg a sheet that are good for light structural work.
    Talk to your local mobile home manufacturers to see how they make their interiors and where to source the plywood from.

    Next on the economical scale I found is plastic honeycomb core from Plascore, http://www.plascore.com/ The last price I had is ~18 months ago $45 a sheet for 10 & 12mm. You can face this with 1.5 - 2.0mm 3 ply or glass them.

    Andrew
     
  7. bobothehobo
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    bobothehobo Junior Member

  8. rberrey
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    rberrey Senior Member

    Cat, I dont know about inexpensive but I will be using all 5/8 foam same as the hull, I bought case price so I just added in interior. When I added up shipping with plywood prices I decided I would break about even going with foam on my bulkheads and furniture. If there is no structural intent in the design of the furniture ect. a cheep foam with no shear strength may do, I think fiberglass supply stocks one. rick
     
  9. Steve W
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    Steve W Senior Member

    kraft paper honeycomb such as verticel sandwiched between doorskin ply makes nice lightweight stiff sheetgoods for a reasonable price. The interior is a good place to save weight.
    Steve
     
  10. Pericles
    Joined: Sep 2006
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    Pericles Senior Member

    I've been asking questions about foam cores after I read about Jorma Ponkala.

    http://shalom.ponkala.net/pages/shalom-boat--in-english.php

    http://www.solarnavigator.net/solar_boat.htm

    http://translate.google.co.uk/trans...ox-a&hs=V0J&rlz=1R1GGGL_en___GB351&prmd=ivnso

    Here is the product specification.

    http://www.finnfoam.lt/client/frontpage//english.pdf

    It's not available in the UK, but here is the text of an email from Finnfoam.

    Finnfoam is xps (extruded polystyrene).
    Xps boards are sold in England at least with trade marks:
    Styrofoam by Dow Chemicals
    Polyfoam by Knaufinsulation
    Styrodur by Basf and sold by FOAMtech Ltd

    Mr Ponkala has during past 20 years made many kind of constructions using Finnfoam and glassfibre. Shalom is his second boat.

    Best regards

    Seppo Paasi

    Thus.

    http://www.knaufinsulation.co.uk/pr...oam_floor_insulation/polyfoam_floorboard.aspx

    Price in UK.

    http://www.building-supplies-online.co.uk/knauf-polyfoam-floorboard-insulation-standard-3243-p.asp

    AFAIK, 20% of the cost of Diab foam cores.

    Cat Builder, search your locale and try a sheet for yourself.

    regards,

    P
     
  11. War Whoop
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    War Whoop Senior Member

  12. CatBuilder

    CatBuilder Previous Member

    Thanks for all the advice, guys. I'll look into them.
     
  13. Pericles
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    Pericles Senior Member

  14. Herman
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    Herman Senior Member

    Also you could do a couple of phone calls, see if you can find a batch of "B-grade" foam. Usually nothing is wrong with it, just odd sizes, thicknesses, or a corner that broke off.

    I also once bought 5 or 6 containers full of thin sheets Core-Cell, in full, half and quarter sheets. That was something. Many structures in Holland were built using these sheets.
     

  15. hoytedow
    Joined: Sep 2009
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    hoytedow Wood Butcher

    There are always bargains to be had. I saved money on plywood by haggling over damaged corners.
     
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