Basket Case,
I have not built an entire boat yet using this material. There were two hurdles to cross. First the cost of Nomex is steep for an amatuer builder. But I found a guy with crates of surplus aerospace honeycomb selling for less than 1/10 retail cost. Needless to say I scooped up over a thousand square feet of core. The second hurdle is difficulty in building tooling the size of a boat hull to process the prepreg/honeycomb material. For builders like Marstrom the tools are a major capital investment. I have a mostly finished F-18 mold but ran into difficulties with porosity of the mold. This can be cured but I am taking a break from the project until the frustration level dies doun and interest picks back up. By the way the, mold has over 600 lbs of glass reinforcement, is over two inches thick, and uses epoxy that can resist 450 degrees heat. It's a very hard thing to make! I have built lots of stuff with prepreg composites and have those techniques down pretty well.

Kevin