On Tue, 28 Jun 2005 06:59:35 -0400, DSK wrote:

Foam core panels do have a number of downsides. They need to be
engineered properly, it's expensive to just build it up 10X as strong as
it needs to be, then start cutting it down until it starts flexing
alarmingly... ie standard boatbuilders engineering. They need to be
carefully laid up for max bond strength, requiring more & better labor,
higher costs. They need to be protected against water intrusion, meaning
that the owner must maintain the boat properly, and this IMHO is the
biggest cause of core problems.

Years ago I became interested in "cold molding" using the WEST system
of wood veneer over a base frame, sans core. A friend of mine back
then built a 32 foot Downeaster style boat using this method and it's
one hell of a boat - it's been through a lot and looks damn near new.

He built a second boat - a 40 foot, full keel sailboat using some kind
of core material (I can't remember at the moment) again with the
veneer and WEST system resins and that boat has been used well and
it's a very solid boat - in fact, the only sail boat my wife will step
foot on.

What really counts is the workmanship. I wouldn't have any problems
purchasing a Bluefin and they use chopper guns to bolster areas of
their hull - it's a great hull, well built and solid as a rock.