However people are looking for smooth finished panels and the additions
of a gel coat and the smoothness adds even more weight. The smoothness, of
course, is a result of the filling in of the weave and gaps in
fiberglass overlap joints.

The Jig method may have some of the same problems but if the foam is
surfaced filled and the glass fiber is placed on the foam before the
resin tacks up, the glass will absorb up to 15% of the excess resin from the
foam sealing resin and glass beads.

I think this should be explained in full to those who are seeking to
achieve the lightest possible panels, so that they might make an informed choice
about which method to select. If weight is not so important the choice
is easier.

In my particular project I'm aiming for the Light Sport category the
target weight is right on the cusp - so any additional weight must be avoided
at all costs.

George Lendich  (Down Under)

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George, Find some lighter weight cloth for the low stress panels.
On this car the body was made from two layers of four ounce glass cloth
with 1/4 inch thick PVC foam core. You don't have to use 10 oz.  When it
came back from the paint shop it was twice as heavy :) It went 230 MPH at
Lemans.

Paul Lamar

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