Inexpensive, Lightweight Core for Interior Uses?

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

  1. Pericles
    Joined: Sep 2006
    Posts: 2,013
    Likes: 139, Points: 63, Legacy Rep: 1307
    Location: Heights of High Wycombe, not far from River Thames

    Pericles Senior Member

    I purchased sets of plans four years ago, for both the DE25 and the LB26 from Using the building instructions of both plans, I am going to build something with a superstructure that resembles the look of a Thames 25' saloon launch.

    The LB26 plans recommend foam core and as the DE25 is the easier hull to construct, I shall marry them together. This is going to be a rivercraft only, so ultimate strength is not necessary. The boat would be so light, only a 15 hp 4 stroke outboard would be required. 2 litres per hour @ 8 kph.

    Knauf Polyfoam is the same specification as Finnfoam, so I have done some costings for UK construction. The DE25 plans call for 28 sheets of 10 mm and 9 sheets of 12 mm BS1088.The 12 mm 5 ply sheets are available @ £43-32 per sheet but it would have to be Robbins Elite 9 mm 5 ply @ £65-55 per sheet, costing a total of £2225. Dat's alotta dosh! :eek:

    Using Polyfoam, 40 mm hull bottom @ £10-51 per 1200 mm x 450 mm sheet and 35 mm hull sides @ £9-27 per 1200 mm x 450 mm sheets, the DE25 plans would require 24 sheets each of both thicknesses, about £480-00. VAT of 20% is ignored for now.

    Foam core requires more epoxy resin and glass cloth, but using Polyfoam would save £1745, which buys a considerable amount of epoxy resin and glass cloth, over and above the 30 gallons etc., that the DE25 plans originally call for:

    Money, money money,
    I must save some money,
    I'm a poor man now! :cool::cool::cool:
Forum posts represent the experience, opinion, and view of individual users. Boat Design Net does not necessarily endorse nor share the view of each individual post.
When making potentially dangerous or financial decisions, always employ and consult appropriate professionals. Your circumstances or experience may be different.