New Deck design for "Feeling39", again :)

Hi again. I have posted a thread last year about advise needed on a new deck for my "Feeling39" hull . Your conclusion was : leave it out , get an original one, and Voilà, job done. Unfortunately , Im a stubborn bugger, and after reading "The Voyager's handbook" decided to change the deck , and the whole interior, so its suitable for round the globe sailing. (as its about time to leave the rat race).
I need something with a pilot house (like Van der Stadt"Samoa"-"Norman" with double steering , with proper U-shape kitchen , tons of storage and the lot one needs .
Ive met a Polish boat designer who says that the easiest (read: fasters/cheapest) way to build the deck without any molds/helixes etc, is to design it in 3D out of "ruled and developable surfaces "(or something like that ,so it can be cut out of 3-4mm ply by CNC router, "stiched(taped) and glued",( once stitched it will gain the desired shape ) then Airex foam , laminate on both sides ,and we've got it. Of course he will do all the structural calculations etc etc.
Ok guys , now, tell me what you think about it, or maybe you have something better than (the Polish method ) . and BTW, HAPPY NEW YEAR to all of you. Tomek

 

Tomek, your designer buddy is on the right track, but CNC cut panels aren't the cheapest, nor easiest way to go. Foam cored panels require a great deal of "goo factor", fabric sheathing and of course paying someone to CNC your panels. Foam can be cut with a knife or hand saw, very easily, which is a whole bunch cheaper than a CNC machine. Secondly, foam cored panels are light, but you have to cut everything three times: the inside skin, the core and the outside skin. With a simple plywood structure, you cut it once and install them on the boat. These too can be taped seam construction and a lot cheaper than a foam core setup. The plywood also needs to be "developed", which simply means they need to be shaped to conform to the limitations of sheet goods, but this is a common task for a designer.

 

PAR, I have that "post_socialist comfort" of having a timber frame factory down in Poland, where everything is still cheaper . and I throw the costs as business expenses . My skilled cabinetmaker, costs me $4 an hour , do I need to say anything alse ? .
Could you enlighten me on those: Foam cored panels., please?
. T

 

The foam cored panels are what your designer has suggested. Price up Airex foam, plus the plywood skins, plus the sheathings, then compare this with straight taped seam plywood panels. It'll become obvious pretty quickly.

 

The foam cored panels are what your designer has suggested. Price up the CNC work, Airex foam, plus the plywood skins, plus the sheathings, then compare this with straight taped seam plywood panels. It'll become obvious pretty quickly.