if your asking me..
I would get access to a cnc machine.
Then laminate up alternative strips of foam and wood (western red cedar or similar) alternatively balsa strips with carbon running between each strip and a central strip of western red.. I have used both techniques. Here I will say having a semi-dense wood core, like western red, at the tips and edges helps when impact happens! So the blank profile is 2 cm of western red 10cm light foam 10 cm western red 10 light foam 2 cm wester red. For a total width of 340 mm. One can use smaller and more strips if one wishes but try and keep the max width with the denser core as well as the tip being totally dense core.

Then glassing skins to the cnc form. Glass or carbon as your mech engineer requires to handle the loads.

I would not use a foam only form unless your really sure of the skin thickness!! Even then the point loading when righting the boat or sailing under hard conditions can be very interesting!!

hope that helps




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