In the previous post, I showed a mock up in cardboard, After a little bench epoxy work, I created composite panels and epoxy bonded them in place. I've yet to round off the corners and tape the edges but this particular structure will serve as a locker for foul wether gear as well as a protective covering for the starboard side cable steering mechanism. A large access hatch will be cut in the face so that full and easy access can be gained to all steering components.
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Tip 1: Hey to get nice rounded corners first make the panel one piece with side + front. Then at the corner location kerf the core with a table saw. Remove about 50% of the core for a width = about 1.5x panel thickness. Then fold panel and fill kerfs with bog. Experiment a bit to get kerfs right.
Works better for honeycomb because you just rout off the inside skin but works ok for foam core too.
http://maiaaboard.blogspot.com.au/search?updated-min=2006-01-01T00:00:00%2B10:00&updated-max=2007-01-01T00:00:00%2B10:00&max-results=20
Search for the May 1, 2006 posting and you can see what you can do with honeycomb.
Tip 2: use hot melt glue gun to help make templates where masking tape won't make strong joints.
Tip 3: used carbon fiber windsurfing masts make excellent interior hand hold posts (table legs, etc.) Craigslist for $50...
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