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So I've built a couple of plywood boards now and thinking of trying a foam core. I built my ply boards with two layers of 6mm ply laminated with epoxy. I put the rocker into the boards during laminating by placing weight on the top with the tips propped up to the wanted height, and they held the shape with very little spring back. I glassed both sides after that. Is it possible to use this process with a foam core? I was thinking about laminating 2 layers of 6mm Divinycell. I'd prefer to hand-layup the boards and not use a vaccuum. The biggest issue that I've come up with this approach assuming it works is how and when to attached the rails. Anyone have ideas?

Any suggestion for an online source for strips of ABS for rails if I decide to go that route?

On another different note anyone have a good online source for paulownia or balsa wood for cores?

Thanks.

I found that link very helpfull
http://freespace.virgin.net/cav.labs/