Step 45: Making Divinycell H80 Foam Core Panels & Peel Ply, Our Tips & Tricks without vacuum bagging 

Amen to this comment. The most notable composite aircraft builders start with a micro slurry over the foam.

Yes but the epoxy will get thicker and not wet out the glass as fast or completely, I recommend just get a epoxy with enough pot life

Thank you!

Hardware store xps needs several things to be fiberglassed well… 1. Sand the entire surface with 180grt sandpaper. The 4’x8’ sheets come out of the extruder with a shiny closed-cell surface. You will have delaminating issues if you don’t open up the surface. 2. Structural panels should then be primed with a thickened epoxy and then start layup when it starts gelling. Non structural panels can be lightly sprayed with super 77 to tack the first layer of glass. But let it cure for at least an hour before wetting out. 3. You will want at least 20oz of cloth on each side for vertical structural panels. For a camper (very boxy, less loads than a boat) I recommend 3 layers of 7 oz plain weave with the middle layer laid at a 45* bias. If you are planning to walk on the roof deck, go 30oz on the top side. Interior Partition panels can go with a single layer of 7 or 10oz. 4. For joints and openings, get 2” and 6” tape in 3 or 4 oz, and 4” tape in 45* bias 6oz.

Thank you!

We went through Jamestown Distributers. I am not sure how the supply chains are right now but for us it took a couple of weeks to receive. Good luck, and thanks for watching.

Thanks for the information. We will have to try this at a future date. 😊

@@BuildingMVDauntless Let us know your results. At a future date.

If you are using pre glassed panels there is a certain way illustrated in Craig’s plans on how to join the panels. Because we are glassing the raw foam without seams we are able to glue the raw foam together with thickened epoxy let dry and glass over the whole panel. Good luck on your build, there may be a ripple in our future as well 😉 😊

@@BuildingMVDauntless Thanks for the fast response, cool having your video's play in the back ground at work here in New Zealand, I am doing the same as you with the foam core and will lay up the glass on all panels. Well let you know how I go on the ripple for sure, I am doing it the other way around and starting on the ripple and then on the cat.....

Unfortunately we do not have enough experience with other resins to give an accurate answer. We have exclusively used epoxy resin over divinycell h80 foam, with very few issues thus far.

That’s awesome! Glad to hear it. We did this video because we didn’t have any references ourselves! Like we said it’s how we do it, it might not be right but it works. 😂

I was wondering why not scarph the panels together, it's a relatively simple process with a handheld planner - just overlap them with the amount of edge you wish to scarph together flip over the one panel apply some thickened epoxy mix and apply pressure to the joint (use peel ply if you wish, sand a bit to remove any extra epoxy that should have squeezed out, and apply your glass as you did! Makes a superior joint, but I guess you weren't looking for the strength of the joint to be an issue

Epoxy Resin from TotalBoat.com!

Thank you! We didn’t bother because of the size of our build… maybe next time 😆

We haven’t found a better way to reduce the amount of resin used. At the moment we are not set up for vacuum bagging or mixing guns.

Carl never did get to this… but we’re thinking you’re not too far off. We’ll have to reveal that on the upcoming q&a!!

@@BuildingMVDauntless Yes please!

Thank you! Good luck to you.

Thank you! We should have mentioned that. It is true for most scenarios but the epoxy we are using does not amine blush (get the waxy surface)! Honestly another (and main) reason why we love this totalboat 2:1 product.

😂

I have seen a lot of people do that. It wasn’t recommended by the boat designers, or our suppliers. Idk if it is because we are using epoxy or wasn’t necessary. For any future builds we may look into that option. Thanks for the input. And thanks for following along our journey 😊

next time you work with glass you can easily do a test patch. You will see the stranded adhere easier and better as it lets the air through better (I think).It sits flat easier. Best practice is normally a slightly bigger piece of chopped, then weaved then topped off with chopped again if strength is the target. @@BuildingMVDauntless

Thanks for the tips and information. Although our project is nearing an end. We are definitely still learning a lot. We intend to do some update videos after we are done, on some of the different tips and tricks we have acquired along the way. Thanks for following along 😊

that's a common misconception that using peel ply and rolling removes too much of the epoxy, not true the strength comes from the combination of the multiple layers of glass, the epoxy and the the core. Too much epoxy and the epoxy becomes brittle, it's a bit of a balancing process.

We haven’t yet had to finish the edges of these panels but it is recommended to rebate the core about 5mm or 1/4” and fill with a thickened epoxy. Another option could be to glass a layer of glass over the edge after the edges are radiused. Good luck with your build 😊

@@BuildingMVDauntless Thank you!

Lol. We try to leave the peel ply on until we are ready to use the panel. It helps keep everything clean. Be sure to check out some of our earlier videos for satisfying peeling 😊

Thanks! We would definitely be interested in vacuum bagging but at this point we don’t have too much left to do! We have the method down to about an hour per side and it works out well for us after a long day at our day jobs! One side and done for the night lol 😂

It sure can. It’s a mess but it is possible!!

Yes, use Thixo in the mix it helps.

Divinycell h80.

The foam is a PVC based foam. It’s extremely dense, not like the feel of styrofoam at all. It is divinycell and you can check it out here! www.jamestowndistributors.com/product/product-detail/1588

@@BuildingMVDauntless Much thanks. Great job the both of you are doing. All the best with it.

Hmmmm....inyeresting technique but hey it works! I know when we work with that foam we drill 1/8" holes in it to transfer resin through this way it bonds everything together.