[quote=Wolfman]Unfortunately I'm too busy doing real work right now. :(
You can buy the structural closed cell poly foam (airex or other brand) from many sources (don't have any handy right now). Or make a mold and use the 2 part expanding foam stuff from US composites. [url]http://www.uscomposites.com/index.html[/url]
Cheaper alternative is to get some western red cedar or balsa blanks for the main body and glass it with fiberglass, carbon or carbon/kevlar. Its denser than the foam, but with a 30 year old boat weight isn't the most critical problem. In the case where you are glassing the blanks having a CNC router would be a huge advantage over having to sculpt them yourself!
There are some good instructions and videos on how to build the foils here: [url][url]http://www.uk-cherub.org/doku.php/tech/howto[/url]. Toughest thing would be if you want to vacuum bag them to get more strength out of the fiberglassing. Again probably not essential if you put a couple more layers on. I have a guy here who does sailboards that I might try and sucker (convince) into making a set of foils for me.[/quote]
No HTML tags allowed (except inside [code][/code] tags)
