Boat Forum / Building / March 2006

Hi all,

I have a large supply of carbon fiber/Nomex honeycomb core aircraft
panels that will be turned into furniture aboard my catamaran.

I'm considering ways of finishing the external seams to minimize the
amount of fairing I will have to do.  I'm going to be making up some
test pieces to break but this is what I've come up with as options for
making the right angle joints:

- all options filleted and taped with 1-2 layers 6 oz x 4" wide tape
on the inside of the seam (inside a locker or settee etc.)

- outside seam options:

1) round over, tape as above
2) glue on an L shaped wooden molding, about 1-1/4" x 1-1/4" length
3) 1) + 2) (cause the molding hides some of the tape)
4) my favourite so far: rebate one edge of inside layer of carbon and
core.  Edge glue parts together so only small seam is visible.  Like this:

       panel 1
=========================

====================[   ]
                    [   ]panel 2
                    [   ]
                    [   ]
                    [   ]

I am not willing to consider veneer over top of the panels because I
don't think I will be able to do a good job, the extra expense, and
mostly, the extra weight.  A painted finish will be good enough for me.

Thanks for any hints,

Evan Gatehouse