Originally Posted by pilgrim
An interesting fact was brought up to me by the Technical engineer for Divinycell. Priming H80 foam takes 300gram of epoxy per sq metre... thats 300g x 8.5sq m for the hull's outside alone... 2.55kg! Another 2.55 kg for the inside as well...

Weight of hull calculation
cloth inside and outside (200g/sqm ) = 3.4kg
epoxy to saturate cloth = 3.4kg
Diviny cell H80 10mm thick = 6.8kg
Epoxy for priming both sides = 5.1kg
Reinforcement ( estimated ) 1.3kg

Total = 20kg




Pilgrim,

I think this is very cool project and am glad you are sharing it with us.

Here are a couple of the issues I see in this process
Have you fully weighed your materials?
• H80 core will vary 25% in actual density. Acceptable density for this range will span the full difference between the H60 and H100
• In theory it takes 300 g of resin to seal the face of the core. We have found the H80 typically takes 20% more as its surface roughness is very high. With hand lam you can under coat the core, but this may cause long term life issues. Cores with a finer surface texture like Rohacell or certain grades of corecell will take significantly less resin but are more expensive.
• Non spec fibers have a weight tolerance of 10%
• Hand lamination and maintaining a fiber/glass ratio is a crap shoot unless you have done it A LOT
• Do not underestimate the weight of the finish – Fairing compound and paint. Paint will be about 2 kg alone. (half gel coat weight) The weight of the fairing depends on how good you want the thing to look and how much you get tired of sanding.
It matters not at the end of the day, but weight is not that easy to control no matter the process. Some of the builders have enough materials they can mix and match lots to keep things tight, or have a relationship where they can not accept certain batches of materials that a home builder might have to.

On the laminate, is this a sloop or Uni rigged boat? Sloop rigged configurations will have significantly more loads and if you are using the LR A class as your model and A has almost no load compared to a 2 up sloop rigged F16. Adding plenty of material to inside hull face between the bridal and the front beam is critical. Hull failures are almost always in compression. Compression resistance is mostly a function of the thickness. Carbon is stiffer than glass but you can get into problems as builders cut to single layers for the carbon and it is difficult to keep it in column.
Single skin also may be great for the design while sailing but will be very fragile, especially with H80 core. Heel dents and damage from shore/rollers and trailers will be an issue. Take very good care of this boat. An A has single skin but at 75 kg is a lot easier to move around.

Best of Luck