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Foam is more flimsy and must be supported by a more dense structure. We will use either closely spaced molds or battens on molds or a combination of the two. A major difference is the lamination schedule. The fiberglass skins used in foam sandwich are much thicker than in plywood sandwich. Building a foam sandwich boat step by step: build a jig. Boating Tips: Understanding Foam Cored Boat Construction. If you're looking at new boats, one of the things you'll have to consider is whether or not to buy a boat built with foam core construction. This is, of course, tough to do if you don't understand exa. Sep 25, �� For example, in a similar size hull, in sea kayaks, production hand laid up fiberglass over foam sandwich hull, vacuum bagged and hand finished, for 17 ft single sea kayak, will weight about 45 to 60 lbs (depending on the accessories, hatches, seat style, etc) as compared to an equivalent hand built marine ply stitch and glue with a single layer of fiberglass and epoxy (hand laid up, no vac bagging), .
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