Care to give a consult on a build idea I have? I'd like to build a special construction body using a moldless technique much like you'd build a boat hull. And like a boat hull, I'd like to use foam sandwich construction. I personally don't want to deal with making the body 3 times in order to create a plug then a mold and then the final piece (and have a big giant mold and plug left over to store somewhere). To me, moldless construction is the cheapest and maybe easiest way to build a composite body. For the foam, I was thinking 1/4" thick. I see that a lot of boats are made from foam strip planking which seems to work well when you're dealing with really thick pieces of foam but for this body, I'm thinking scoured sheet planking over a jig with battens would work. I plan on doing all hand layup work since pre-preg and vacuum bagging is an added expense I'd like to avoid. If you're willing to give complimentary consult, I'd appreciate your input.
Feel free to PM or email me or reply here. Thanks!