This is awesome you should get the Nobel award for common sense engineering even though My hands shake I can still do it thanks

thanks for sharing! I will apply these techniques you taught me to components of a tiny "airstream" trailer I'm building to pull behind my ebike.

youu gave me an idea for a camper build thanks

Very nice work very professional

thank you!!! I'm planning to make a roof top tent and camper and this technique looks great for keeping it light and strong. Thanks!!

Great job. Doing some research for a Teardrop build and got a few great ideas off you.

Thank you so much for sharing this!

You are making me reconsider using traditional plywood core on my next project. Excellent detail and presentation in this video.

Excellent video and descriptions

Thanks! I’ve been using honeycomb/fiberglass panels I bought at Boeing Surplus 30 years ago. No more of those available, and new 4x8 panels cost $1800 ! So I may give your method a try.

Nicely done. Thank you

Cool! Very handy stuff!

Thanks for sharing video. This process is a bettercost effective way than buying panels and plastic honeycomb is better than cardboard honeycomb. Filling the edges and staggering joint method is a great idea!

Great video thanks

Great Job. Other alternatives are very expensive like coosa. Plywood is heavy and prone to water absorption. Looks like you have the best of both worlds.

Excelente tutorial sencillo y novedoso.Saludos desde Panamá

Nice tutorial and example of products usefulness

Thank you!

Very helpful!!

Cloauth... God bless the east coast.

Really cool man thank you for making this video and goid job

awesome tricks im going to be building a tiny camper this way

Great job and I like the way you have shown diagrams of the different joints etc . I want to remove my splash well to make more deck space and will need to make some support walls . I will use your principles with 1" foan core . Thanks again for both the ideas and the methods .

Nicely done. I am sold on this material for strength, rigidity, and relative cost-effectiveness. I researched these materials extensively a few years ago, and conducted many experiments thereafter. Two comments: WATER INTRUSION: Plastic honeycomb has a troubled reputation for boatbuilding where water intrusion is possible (hulls). First, know that the plastic (core) does not bond well to polyester or epoxy resins, instead, the resin bonds to the "skin" which is a polyester-impregnated cloth. When it happens, the fiberglass wall (including the skim cloth) separates from the plastic core and water enters through the separation, essentially filling all the cells therein. It's not a deal-breaker but rather means that any penetration or crack is a vulnerability and must be repaired/resealed immediately. EDGEWORK: It was good observing the attention to the edges because the edges are among the weakest parts of the final assembly. I am not familiar with the epoxy putty used but I would be a little concerned about bonding between the plastic core material and the epoxy putty (often weak bond results). One way to overcome this issue is to "activate" the surface of the exposed plastic core using the activator found in Loctite 2-part "Plastic Bonder" with a plastic-specific adhesive such Devcon Plastic Weld or a methyl-methacrylate (MMA) construction adhesive. All that is needed is a thin coat because (epoxy) resin bonds fine to the adhesive. I make 100% strong edges and bond sheets this way. YMMV. Good luck!

Excellent information, thanks for sharing.

VERY NICE

great video. I haven't been able to find the honeycomb material though.

Good tutorial. I do have a suggestion: instead of wetting out the Matt cloth on the honeycomb or cardboard, use some plastic sheeting laid out flat, wet it out, then squeegee out the excess, then lay it on the honeycomb that has been wet out. This way you cut down the weight with no loss of strength. Roll it like normal to get good contact.

Thanks

I enjoyed watching this video. Good presentation skills (voice, pacing, what you show). Will subscribe as I did check out your channel and was impressed by the many different topics you have in your channel.

For things that will not be in the sun, you can put one layer of 4 oz surfboard glasscloth over the honeycomb with polyester resin or epoxy, then go over that with the clear countertop epoxy. Use a torch to break any bubbles and keep dust away until it hardens. All the resin and glass become transparent and you clearly see the honeycomb pattern in the part. I did some ceiling panels and a countertop with honeycomb and countertop epoxy and the 3-D honeycomb looks awesome! You can't use it for anything that will be in the ultraviolet because that will make the countertop epoxy get all alligator-skin.

That bondo glass is great stough I built a covetable truck for my sons in high school I shaved out the tail lights on it useing fiberglass mesh fiberglass and bondo glass ten years later it was still perfect also used marine tex on the convertible top kit super strong stough!!!

Awesome Video...found it! NIDACORE HONEYCOMB SHEETS except generic! Thanks

Do you know what the material of the honeycomb was? I have been looking for a suitable core material that is flexible. This looks perfect.

Very interesting, I sure would like to see the whole build, and yeah wood is easy but the glass is forever,,, almost

I was gonna use aluminium to make the frame when rebuilding my crescent 434 but might just go with this instead. :)

I wonder if I could build a camper using this method. It should really cut down on the weight.

Hello, thank you for the video. Great information. NIDACORE HONEYCOMB SHEETS except generic Cheers

Curious on suppliers, we are landlocked so not a lot of boat repair supply places close by. I want to rebuild a couple seats in my ski boat ones is a 80 in who makes the off brand honeycomb?

Great video! What's the name of that honeycomb sheet? Is it a plastic sheet or a fiberglass sheet?

I am pricing out my costs, can you give an estimate of how much resin is needed per side of a 4X8 sheet of honey comb with the biaxial cloth. Great video, thanks.

I hope you meant to say that you applied a coat of resin to the honeycomb core as you cannot saturate core if it does not absorb moisture.

An important question: How do I make the fiberglass surface smooth? Any type of fiberglass fabric has a smooth surface

This looks about perfect for building my little folding camping boat, whose largest panel is 4:5'/137cm x 1'/30cm. Your tutorial has really helped and inspired me as weight is important as this will be towed as a bicycle trailer on the road. Push button Q/R axles (as fitted to wheelchairs) will take Brompton 16' wheels, a Q/R towbar attaches to the bow. The tailer size is 4:5'/137cm long x 2'6"/76cm wide x 2'/60cm high, and when unfolded the boat will be 9'/274cm long x 2'6"/76cm wide x 1'/30cm high. Kayak paddle or small outboard motor for propulsion. The weight saving will be significant over marine plywood, and this method provides additional flotation and insulation. A collapsible/folding cabin provides sheltered sitting and sleeping space.

any idea how much resin it takes to do both sides of 4x8 panel .Thanks

Hello, congratulations for the beautiful work, please answer me, do the holes in the honeycomb have a vacuum?

You've probably already walked on similar panels, but with a paper honeycomb. I'm looking to build a DIY boat and plywood is expensive now. If I'm reading specs correctly, a same size sandwich of this stuff should be several times as strong as the plywood.

Thx for vid. I'm currently looking at options for making a Wingfoil board. Traditionally they are made from EPS / styrofoam blank skinned with cloth/resin like a surfboard but .. wondering if I might use your technique - what really peaked my interest was the ability to introduce bend to matrix core before glassing. I could shape rocker right in from get go. I'd have to laminate a few to get thickness then shape /fair out with final wrap in carbon cloth. Do you happen to know how much a full panel weighs dry? I read through comments but didn't see. Fewer finishing layers of cloth probably required with this stiffer stronger core. Great vid - thanks again! Now the real challenge - finding this stuff in Canada!

Can I build a live well with that?

Curious why you chose this over say XPS foam panels? If you take 1/2" thick XPS foam sheets and put (lower weight) fiberglass on each side of each panel and then put them together, it becomes very strong and stiff. You do have to scruff up the surfaces really well though.

Water will collect in the honeycomb if the fiberglass is compromised. I've seen gallons of water drain from them

Well this stuff is readily available but this is cheaper and it's better and safer to work with than Aramid Phenolic honeycomb...stuff is bad for you. As far as removing honeycomb goes, in the Air Force and other aircraft industries we'd use a 90° scriber tool in a drill which allows you to remove material below the sheet and we'd fill with microballoons (it's very strong and very light). You're doing great work here for the DIYer.

When you say mesh do you mean chop strand mat? How many layers of 1.5ozCSM and 1708 did you lay to get it rigid enough for the deck?

Did you consider using a closed cell PVC foam for the core? Also, how is the fiberglass adhesion to the honeycomb compared to other materials?

Great vid, thanks I'm considering using panels like this for a deer blind. Where can I find sheets of honeycomb?

What prevents the epoxy from filling all the honeycomb holes and making the part heavier?

Came across your video by accident. Do you have any insight into its strength in compression edge to edge. I need to fill a gap between a hollow formed by a vehicle's fiberglass body molding. Think of it as wanting to use the honeycomb vertically replacing the straight line of the letter D

thankyou ,very Informative videoes i am almost 60years of age and i bought my first boat before my first Car ! over the years i’ve owned 17or 18 boats of all sizes ,Makes ,and Models as Well as Materials you make using the Honeycomb board a lot easier than it really is but you definitely offer some great advice and Tips , i myself am now retired and i did ProfessionalWoodworking Professionally for over 35 years watching you cut out the HoneyComb boards with the Oscillating tool can be accomplished much faster with a Router and some simple Jigs for that Router a good group of Reasons for this is because of the many different Routers and Bits Available and Used inThe Woodworking Industry they are also IMO reasonably priced and Available along with providing excellent Accuracy with Speed , for myself being Retired i’m probably going tom”Binge” watch your channel in preparation for my next Boat Project I grew up inFlorida , and am in the Process of moving back there soon as my grownChildren and Grandchildren reside there now and we do have plans on either Restoring or Building a Vessel as you stated using any type of Plywood Core usually does fail over time and with the Pricing of most Pywoods compared to the Honey Comb Core Board it just makes more and more sense to have that as the GoTo method as opposed to a Cold Molded Process and in all Honesty i’ve gone down the AllWood TraditionalHonduras Mahogany Boat route yes they are Beautifull in many ways but i like being out onmy Boats not always working on them , so i admit i committed the CardinalBoaters Sin before i listed the Woody for Sale i already purchased. a newer ,repo we’re Sport Fisher Plastic (Fiberglass ) boat as my main Cruising and Fishing Vessel

Di you buy the panels from reinforced plastics lab in Farmingdale? I was going to give them a call but figured if this was the place

I’d use a router to make the inlay cuts instead of the oscillating multi tool.

A 4inch diamond edge disc cutting tool is best to trim fibreglass in my opinion

Thank you for tutorial, Do you think you think it could be used to build furniture, like kitchen cabinets? Can it be coated to look premium? What is the weight difference between this and plywood?

is the plastic honeycomb core pretty cheap? (cheaper than nomex/aramid honeycomb?)

Any reason you can't use biaxial on both sides?

where did you purchase those plascore honeycomb sheets what size are you using?

What keeps the glass delaminating from the smooth honeycomb plastic?

Is the biaxial on bottom or top of your deck?

Can you not just use a stanley knife and the putty to first put together the shape and then once that has set and is rigid lay up the fibreglass and add fillets between joints, also wett out the fibreglass between plastic sheets.

Could you use this technique to cover a greenhouse?

Did the boat test positive for covid ?

Can you build a hull from this?

How would this work as a painting substrate for art?

On the edges, a good polyurathane caulking seems to be much easier and more durable than bondo epoxy. That stuff isnt wp flexible or durable. Yes, fiberglass will be better...nice work

Generic panel brand name/source?

the issues is screwing into in and the screws staying put...

I'm 100 miles from the closest city, exactly where do you think my "Local" fiberglass supply house would be ? lol

$60 per sheet?! That’s so inexpensive. Which vendor did you use?

lol why not just cur the pieces put the pieces together and then fiberglass coat them them???

Honestly, I love the end result. Fiberglass and resin is pretty awesome. However I hate that material. It´s dangerous chemicals and the fiberglass is dangerous and can be bretah in. You also have to wear a mask while sanding and cutting it and so on. I really hate that.

Very interesting. I submit that honeycomb panels are not a 1 to 1 equal to plywood when it comes to stiffness and they deflect more. Here is a video showing that: kzfaq.info/get/bejne/npqSdNOkvbnFpoE.html But since the stiffness of an object increases/decreases by the cube of the increase/decrease in thickness. if you double the thickness of some material, you increase stiffness (resistance to deflection) by a factor of 8 (ie, 2 cubed). So a 5/8 inch thick honeycomb would likely surpass somewhat the stiffness of a1/2 inch sheet of plywood and still weigh much less.