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Old 06-18-2021, 09:19 AM   #1
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Looking for a foam sheet for decking

I am repairing a soft flybridge and i am having trouble finding corecell sheets locally ( in Virginia) . Anyone have any experience with an easily sourced foam sheet that is compatible with epoxy resin for filling the voids? Btw, my core is 1 inch thick. TIA
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Old 06-19-2021, 03:27 PM   #2
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Have to ask, why has the existing core gone soft and what was it?
Why does it have to be corecell?
Could you not use divinycell, termanto, strucell, nidaplast/nidacore, klegecell, gurit, all compatible with epoxy.

1 inch is VERY thick for a core.
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Old 06-19-2021, 04:00 PM   #3
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Prior core was balsa. Went soft from total neglect from previous owner. Bimini wasn't waterproof, windows unzipped for 2 years and obviously there is intrusion somewhere but hard to find when entire deck is soggy. Open to other cores just hard to find.
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Old 06-19-2021, 04:18 PM   #4
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How structural does it need to be?
I am guessing if it's 1 inch core it must be a large unsupported panel that gets heavy traffic?

If it's not highly loaded and they simply used balsa as a cheap filler, XPS may be enough?
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Old 06-19-2021, 04:20 PM   #5
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I would think about using 2 layers of 1/2” with some glass in between. While I am not a structural engineer, I think it would end up stronger than a 1” core.
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Old 06-19-2021, 04:27 PM   #6
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Heavy traffic. Flybridge walkway.
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Old 06-19-2021, 05:59 PM   #7
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The 2 layers of 1/2” should work well in a heavy traffic area.
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Old 06-19-2021, 06:23 PM   #8
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2 layers of XPS?
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Old 06-19-2021, 06:35 PM   #9
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Quote:
Originally Posted by Bradlesh View Post
2 layers of XPS?
I wouldn't
Saying that multihull designer Kurt Hughes from memory used ply xps ply to do bridgedeck panels on large catamarans so that would be up for the job
And I have seen same panels used for cabin sides and roof on other structures.

Logic says that XPS could,would, should work with glass but it would need a much heavier glass layup as the foams compression strength isn't that great.

I should add, those panels I am talking about are much thicker.
BD panel around 100mm and wall roof panels around 50mm so no, I don't think XPS would be a good choice for your project
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Old 06-20-2021, 05:36 AM   #10
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Are you going to attempt to replace it in place , or lay up the unit on a shop floor?

If it is to be an external layup it is super easy to add stringers for stiffness to the inside , before flipping it over to do the exterior.
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Old 06-20-2021, 06:05 AM   #11
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There is a Distributor in Norfolk that stocks Coosa Board. They deliver in their own trucks to dealers and boatyards in VA and the surrounding States



https://shop.paxtonco.com/storefront...chType=keyword
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