The main body is 2" foam insulation board used in homes. I ended up using "green" from Lowes instead of the normal Corning pink. So, it started as a bunch of foam sheets.
The first step was to epoxy two layers of foam together in the rough shape of the hull. It is vacuum laminated using a big sheet of plastic folded over and duct taped together and a shop vac. Since my shop vac is crappy, I bought a refurbed vacuum pump to laminate. The second picture is of the hull while laminating (left under vacuum for about 30 hours).
(You have to put blankets over and under the vacuum hose to allow even air flow through the vacuum bag.)
Reply With Quote