How can I make cheap honeycomb core boat hulls

I saw a 'How It's Made' episode where they revealed how to make honeycomb core simply by making a paper accordion, expanding it, dipping it in resin then sawing it into cores. I WANT TO DO THAT!
They said they used a thermoplastic paper as well as a heat-activated glue. But why couldn't I use a cheaper more readily available material?
Does the resin provide ALL the structural strength, or does the thermoplastic paper itself provide the strength? I would assume it's like fiberglass, whereby after it's infused with resin it's super tough... but the fiberglass itself provides strength too...
What kind of material could I use for this? Straight up craft paper & elmer's glue?

After the cores are cured and cut, I'll sandwich them between various layers of either wood laminate, plastics, fiberglass, or carbon fiber.

Thanks!

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rickharris4 years ago
http://www.youtube.com/watch?feature=player_embedded&v=txSboSNQINs
A superb video on material application.

BTW Elmer's glue is always water soluble, even after it has dried.
YEP sure is! Although it takes a lot of soaking to get it to give way.

the aerosol foam is p[perhaps one of the best "glues" to use in waterproof situations with porous surfaces.

Works especially well with boats although it has poor shear strength.

A lot depends on what is CHEAP! Cardboard is cheap and honeycomb hence my first link.
If your looking for very light weight then have a look at these designs:

http://www.gaboats.com/boats/

I doubt there is a way to get lighter then these.
jmlidea (author)  rickharris4 years ago
I've seen those designs and love the skin on frame approach. I'd like to build a multi-hull craft, likely a trimaran, for some extended open water voyages. Although safety isn't number one, it's number two, number one is given my measly budget can I afford this?

Also, I love cardboard as a building material, I know I could include cardboard into the aesthetic of a hand-crafted boat, somewhere, maybe as a ornamental piece or as furniture (collapsing cardboard benches perhaps)

A trimaran's hull needs to be stiff, also, and a SOF boat loves being flexible... but it's also quite cheap, durable, lightweight, and doesn't require toxic fumes, chemical suits, gas masks or huge amounts of space. I could build a boat piece by piece, store it, then assemble it later as opposed to building a fiberglass boat all in one place.

I'll look into the aerosol foam glues and do some strength and water tests. Building my own honeycomb core would be cool, especially if I could get it into a working boat!
If your looking for a large boat to sail extended distance away from shore DON'T STINT!

Do the job properly with approved materials - Where safety i concerned there isn't any real point if cutting corners.

Phil Bolger has some very innovative designs for the home builder - I can recommend the book Instant Boatbuilding with Dynamite Payson.

Mostly stitch and tape plywood construction but included larger boats that may suit your needs.