Polycore Has just launched a Pre glassed panel !

Discussion in 'Materials' started by maggie42, Jun 13, 2013.

  1. maggie42
    Joined: Aug 2008
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    maggie42 Junior Member

    Hi Every one

    I am just keeping you up to date ...
    and looking for feed back as well


    This is currently for Australia only
    but the USA is comming on line soon..

    Polycore is now offering ready to use epoxy and fiber glassed panels..
    These are off the shelf start up boat building panels

    These offer the boat builder or home handyman a quicker low cost 1st layer of glass on the core panel

    And many find that they can now pre fab alot of the boat
    As the 1st glassing is all done for you!

    You can now set the boat up with these ready glassed panel sheets

    Tag and glass them together to form the general boat...shape
    and then finish off with the final layer of glass and paint.

    This cuts back alot of man hours....

    Price is a bonus as well
    Currently 15mm with 1mm glass $77+ per square meter!

    The other thing that Polycore Composites Has done is
    This same pre glassed panel can be supplyied in a single Monster sheet up to 11.9 meters x 2.4 meters wide...

    For house boats....etc.

    Cheers Maggie
     
  2. waikikin
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    waikikin Senior Member

    Sounds great Maggie, how much for the big sheet?
     
  3. maggie42
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    maggie42 Junior Member

    Hi

    For the 1mm Polycore Pre glassed panel 15mm
    it is the same price per square meter $77+
    for a 2400 x 1200 sheet = $223+

    Their is no price change if you require a larger over sized panel.

    You cannot get marine ply, balsa or foam already glassed for that...

    This new Pre Glassed Polycore panel is going to open up new projects and assist in keeping costs down as well...

    Cheers Maggie
     
  4. waikikin
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    waikikin Senior Member

    Couple more questions.....So what glass is on each face of the panels? & what is the surface finish to each side?

    Jeff.
     
  5. maggie42
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    maggie42 Junior Member

    Hi Jeff

    They are made with epoxy and a light layer of woven rovings, just enough to kick start the panel off as a composite glassed core panel.
    We can do 0.5mm glass or 1mm glass... for the marine market.

    Over the years..
    We have had alot of home boat builders ask us
    Where we can suggest or direct them to go to have our panels glassed up for them...
    It was due to this ... we developed the pre glassed panel.

    The saving with labour time ..is massive
    compaired with setting up lay up tables to make their own panel....


    The finish is 99% smooth on both sides of the panel.

    This allows the boat builder a good working surface to key the panel up and to add what ever they need glass wise ...
    Double bias to Quad to the Polycore pre glassed core panel

    The idea was to have a light weight universal panel to suit the many jobs that he is doing from bulkheads to hulls or simply fit outs and furniture.

    So many boat builders spend so many hours setting their panels up on tables for the 1st layer of glass....

    This Pre glassed honeycomb core panel is now able to be pulled simply off the shelf .... and he can now add the extra glass to this panel for what ever job is on hand to do...

    I hope this helps Jeff

    Cheers Maggie
     
  6. Timothy
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    Timothy Senior Member

    I am considering building a boat that has no component more than 6 meters long . There are no compound curves and the design is for stitch and glue . If building using your panels I would presume that after cutting the panel to shape the edges would need some of the core removed and then filled before stitching the panels together. If made on a table the panel edges would have been rebated to accept the fiber glass tape to facilitate a smooth join. If I were to use your panels could they be made with the laminate complete as they would be if infused on a flat table and how would I deal with the rebate issue?
     
  7. Alik
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    Alik Senior Member

    Good bye, ATL! :D
     
  8. tomas
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    tomas Senior Member

    What is the minimum bending radius with respect to the panel thickness?
    For example, is it 100 x panel thickness, 50x's, 20x's or ?
     
  9. maggie42
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    maggie42 Junior Member

    Hi Tim

    Yes...
    The stich and glue can be done...it is a little fiddly

    I am currently doing a little project of a retro tear drop caravan...with the 1mm pre glassed Polycore panel

    And I have routed out the whole edge of the core and just left the very thin 1mm of glass exposed.

    it is with this fine exposed glass that I am going to interlock and join to with my next routed out panel.

    And the rebate fits snugly together

    Once I have the 2 routed out peices fitting neatly together I am going to tie them carfully into place just to hold them

    Then once they are nested nicly i will do further glassing over the whole join on both sides to perminatly fix into position....

    The thing with stich and glue is you are just temp tieing the panels together..... for the glassing over.

    it is the over all 4 inch to 8 inch wide glass tape that is giving you the real strenght over the whole join

    Many people go wider in glass tape to spread the load over the whole join.....

    Cheers Maggie
     
  10. maggie42
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    maggie42 Junior Member

    Hi Tomas...
    The Polycore pre glassed core panel is ridgid

    But with the 0.5mm glass you can crack the glass a bit to bend it ... not imposible .. see below

    Just like you would have a glassed foam or balsa panel...


    But
    The PP8H thicker core with no glass can be simply curfed on one side of the panel
    This is done with circlar saw blade cuts to bend the core.... but you have to be care full not to go right through the core as you do not want to disturb the film and scrim on the other side
    ( unless you want to make more work for your self)

    Once you have done the cuts and you have reached the bend you required you can hold the panel into that position and apply the glass to that side.

    What you will notice is the open cuts that you have made on the inside of the Polycore panel will all close up and meet the scrim as before....

    As to your question of bend ..... the thiner 10mm to 15mm
    core bend well.... 4mm and 6mm you can roll nicely.

    But with the thicker core
    because you are removing the core in the cuts and opening up the voids..
    you will be able to work with many thicknesses of core.
    it all comes down to how many cuts you apply.

    The key is to not do too many cuts..just enough to start off the bend.... and to keep a bit of scrim intact as this is what you are re glassing to.


    Once the cuts are done you can bend the core to suit the bend.... etc

    I hope this is what you need to know...


    Cheers Maggie
     
  11. tomas
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    tomas Senior Member

    Thanks Maggie.

    It was silly of me to ignore the pre-glassed rigidity.

    On your website, I am not seeing the other dimensions you referred to in your post.
     
  12. maggie42
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    maggie42 Junior Member

    Hi Tomas

    It is difficult to put it all on the web site...as we can supply in 1mm increments!!!!!
    www.polycore.com.au

    As we service not only the marine industry but transport and special needs and the unusual industries in the honeycomb world as well!

    But in a nut shell we can supply with the pre glassed panel.
    0.5mm , 1mm, 1.5mm, 2mm 2.5mm and 3mm
    glassed up on the PP8H honeycomb core

    It is the 0.5mm and the 1mm that is mostly used in the marine field, as people can add the extra different types of glasses to these min thicknesses of glass....
    To suit what ever job they are doing.

    As you can see this is a very low cost start up panel....

    To give you a better idea of what it can save for you
    As an example....

    By buying in sheet packs 1mm glass
    15mm P.G panel with 1mm glass is $66+gst per sq mt
    20mm P.G panel with 1mm glass is $77+gst per sq mt.
    25mm P.G panel with 1mm glass is $88+ gst per sq mt

    By buying in sheet packs with 0.5mm glass
    10mm P.G panel with 0.5mm glass $53+gst
    15mm P.G panel with 0.5mm glass $60+gst
    25mm P.G panel with 0.5mm glass $72+gst

    We also supply core PP8H from 4mm 6mm 10mm 15mm
    19mm 25mm 30mm 40mm.....

    And these are in 2400 x 1200 sheets of core..
    We can on special needs supply a larger sheet of core only
    2.6mt x 1200mm

    But this is another story.....

    Cheers Maggie
     

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  13. groper
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    groper Senior Member

    So Can the customer choose the fibre weight and fibre orientation of the panel? I mean can I specify 1000gsm quad per side or 800gsm dbl bias per side or 750gsm triax per side etc etc?
     
  14. Mark Cat
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    Location: Michigan

    Mark Cat Senior Member

    maggie42,

    Not dealing much with these types of panels, perhaps you could help me in answering a few questions.

    In making a panel, why do you need to use epoxy and glass to form the outer sheets?

    Why not just use plastic sheet which will except the a bond from a composite joint?

    That way the panel could be made in a single process and not be exposed to variability in epoxy application.

    Also, what is gas is inside the honeycomb structure after manufacturer? Air?

    All for now,

    Mark Cat
     

  15. Timothy
    Joined: Oct 2004
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    Timothy Senior Member

    "So Can the customer choose the fibre weight and fibre orientation of the panel? I mean can I specify 1000gsm quad per side or 800gsm dbl bias per side or 750gsm triax per side etc etc?" This is the question I wish the answer to.
     
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