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wrote: What techniques should I research for changing the hard corners where two ply surfaces connect? How do I shape those round edges smoothly to have a professional looking curve? Plywood seems to be a good core for the large surfaces. I may use two or three 1/4 ply layers glued with epoxy. 1/4 inch ply will allow some curve to the sides and top, and having multiple layers will provide strength. This is a 50 foot boat, so 1/2 to 3/4 inch thickness would not look too flimsy, and the boat can accommodate the weight. You are going to end up making a male mold and then doing a classic "one off" construction. I definitely would NOT use plywood as a core material, but rather use 1/2" Divinycell foam. Best guess is probably about $3/sq ft for full 4x8 sheets. Probably get the job done with 2 sheets so estimate maybe $200 for foam. Foam can be cut into strips to go around corners, I've done it several times. You do realize that this will be at least a 2 year project and cost at least $1K before you are done. Lew |
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