how to finish seams of cored panels?

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
=========================
||||||||||||||||||||[ ] rebate in 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

I'd lean toward rounding off, as the tape is more likely to lie smooth than
it would over a sharp edge. Too, wobbles will be less visible in the
rounded corner.
I'd plow out the core an inch or so back from the outer corner and fill the
void with a strip of foam. Then do the rounding and taping.

Is there more of those panels available?

Jim
"Evan Gatehouse" <ceilydhNO_SPAM DeleteThis @3web.NOSPAM.net> wrote in message
news:44223b48$1_1@news.cybersurf.net...
> 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
> =========================
> ||||||||||||||||||||[ ] rebate in 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