Polycore Composites

As of October 2013.
Polycore has offices in the USA.
The Company name is Polycore USA LLC
 based in Las Vegas NV. 
Polycore has appointed Rev-Tec Distributor for North and South America 
  Ian Cambell's self designed cat.
Read the whole story in The Coastal Passage.
Cut and paste this link   http://www.thecoastalpassage.com    
Launching Issue 40.   Page 22.
Read about the build in previous issues of the magazine.
This boat is built totally from Polycore.
Nobby's Engineering in Sth Australia sent these pictures of a prototype off road caravan he built with Polycore and fitted out in plywood, he tells us the next will     be all Polycore.


A Col Clifford design with his aluminium skeleton clad with Polycore™ for the hull skin, decks, super structure and furnishings.
How's this for a quick build!
A racecar transporter in 6 weeks by one man!   PETER WING of WINGY'S Racecar transporters Canberra!
Great News from the North: 14 metres x 2.4 metres in one piece!
Bruce Hodgens 11th March 2007.

Hi Maggie & Bob

Just thought I would let you know how I was getting on with the Polycore panels you supplied for my 14 metre powercat.  I received 130 sheets (in 19, 25 & 30 mms) a few months ago and I have started making all the components such as bulkheads, bridgedeck floor, roof , furniture, decks, floors and all the upper hull skins.  Basically other than the hulls below the waterline all the boat will be made from Polycore flat panels, some of which will be bent to 2D curves.  As you are well aware I spent considerable time researching different materials for the boat and now that I have started working with Polycore I am convinced that I chose the best product. I will save nearly $34,000 using Polycore versus foam or balsa pre-made panels.  As a back of envelope calculation a 19 mm panel of Polycore costs $100, and then with one layer of 600 grams/metre2 knitted glass on each side with vinylester resin costs about another $40.  Pre –made balsa or foam panels cost  >$400.  I know this doesn't take into account the labour to make the panels, but you can sure get a lot of panels made for $34,000 worth of labour.
There are plenty of advantages to making your own panels other than cost savings.  Originally I was going to use balsa panels but when I experimented with this there were all sorts of problems.  For example the balsa soaked up a lot of resin into the end grain so I found I had to apply a thick coat of fast curing resin and then when that had gone off I could then glass over.  The next problem was that large sheets were impossible to turn over because the balsa had no inherent strength, so then I had to look at making a flat table and glassing one skin then vacuum bagging the core on, then glassing the other side.  What a drama, and also a huge expense for the vacuum bagging gear, moulding table and consumables.  With the Polycore I just glass one side in the morning and turn it over and glass the other side in the afternoon.  I found we could use AutoCAD to nest all the components and then join multiple sheets together reducing the wastage. I then glass them and turn them over, none of which I could do with balsa.  This is working so well I built the bridgedeck floor in one piece – that was 8.4 metres x 2.4 metres (i.e. 7 sheets joined together) and I have just finished the first of the topsides for the full length of the boat which will be 15.6 metres x 2.4 metres in one piece (13 sheets).  It takes 6 or 7 people to turn these over to glass the other side, but it is no drama.  I will have the complete side of the boat in one panel with no joins and it can be faired and undercoated ready to stick on. What a joy to have all the fairing and undercoating with gravity to help you instead of doing all this on the boat. Making these large panels has reduced the time spent joining multiple panels with fibreglass tapes, creates less work for fairing because the joins always make more work, and we have a lot less waste. 
Of course there are other benefits for Polycore panels.  I was concerned about balsa panels because we have had a few problems with boats here in Townsville getting water in the balsa core, leading to rot.  All the claims that the water will only go to the next glue line in the balsa i.e. at the most 100 mms aren’t quite what happens in all cases.  If water gets into panels it can also move along under the glass delaminating it from the core and spreading the rot to a much larger area. Polycore is polypropylene plastic and so rot isn’t a problem.  One of the tests I have done with sample panels is to beat the living daylights out of them with a hammer.  This is my crude impact-testing regime.  The first time I did this was when a couple of local boat builders dropped in and were asking about Polycore’s strength.  We grabbed a 25 mm scrap that had been glassed with 2 layers of 600 gram fabric on both sides - it was part of a main bulkhead lay-up.  We placed it on the concrete and then swung the hammer hard onto it.  Not a scrap of damage.  In fact the hammer just sprang back off the panel.  After about 5 or 6 hits on the same spot the glass started to get damaged but certainly not as much as any of us expected.  This led to all sorts of further “highly scientific” testing such as driving the car over it repeatedly, putting it between blocks of wood and jumping on it, and suspending it between stools and dropping heavy steel pipes end on from the roof of the shed.  I am impressed with the results.  Particularly interesting was the steel pipe dropped onto the suspended panel.  The glass in the impact side eventually got damaged but the lower surface glass remained intact until eventually we managed to butcher that as well.  At all times we were very impressed with the core strength.  It seems to absorb a lot of impact rather than just transferring it to the inner skin and damaging that. Delamination of the tissue or the core wasn’t a problem either. 
I would be very interested to see some test results that compared Polycore to other types of cores such as balsa and foam.  However for the use I have for the panels I am more than happy with our results.  I will certainly be recommending Polycore panels to all my friends who are building or planning on building boats.
Kind regards,
Bruce Hodgens
Please be aware there are companies in the market place selling product and calling it Polycore this product may not be our ADVANCED HIGH QUALITY CORE! 
We have been made aware by people who have gone to suppliers, and have asked for Polycore™ by name, and have, it seems, been sold other manufacturers products, these people have been assured that these products are Polycore™, these practices are disreputable to say the least, if you ask for Polycore then you should be supplied Polycore!
       If you are wanting the best core in the marketplace, then be sure to ascertain it is a genuine Polycore Composites Product. Our product is stamped as Polycore Honeycomb™ and has the grade of the core stamped on it as well, this grade marking is S for standard H for High Strength F for flexible SF for super flexible, SF is not for structural use, but is used to form complex non structural shapes. If you are uncertain of the product that you are intending to purchase, then please call us to verify whether it is our core or not, be sure, be safe, not sorry!  
Polycore Composites Pty Ltd is now able to offer a Polypropylene Honeycomb in high strength, standard and flexible grades to suit all fabrication needs.
ISO: 9001/2000 aproved panels now available>
For the Marine Industry a DNV certified panel is going through the final approval procedure and should be available in Australia in the near future.
Take note!  Expandable aluminium honeycomb is available as special order! Fire retardent Polypropylene Honeycomb is available now, should you require special core sizes or thicknesses please contact us with your requirements and if we don't have stock we will do all in our power to aquire your needs. 
The following was found on the www.themultihull.com website in the forum under materials:

Just an update on my polyprop cored deck replacement on my Seawind 24.
I managed to beach the boat on Sunday and replace the rotting ply versions.
It has worked much much better than I expected. The stiffness is way beyond my expectation.
I bolted on 50mm x 3mm flat aluminium that slots into the original sail track for the tramps.
I covered it in the same outdoor carpet from the original decks
There is more flex in the central console than the decks. The result is it actually stiffened the console.
One other unexpected benefit was that the deck no longer gets too hot to walk on as it did before (the sun is hot here in summer). This leads me to believe it may have some fantastic insulation properties
Would I build a boat from it? In a flash!
I'll post some pics after easter of the end result.

G'day Tony
What thickness Polycore did you use for your decks, and did you add any stiffening webs underneath?
I spoke to the guy at Polycore in Q'land the other day,and he was very willing to advise... the price of the Polycore was only a little more than I was quoted for the same thickness sheet of marine ply - and a fraction of the weight. You'd have to factor in the weight of the interior f/g too, but you'd end up with a much lighter boat.

As per earlier post(have a look at the first lot)
Core is 15mm
600db top 400db bottom
4 x 34mm pvc tube half pipe glassed over with 400db for webbing.
If I did it again I wouldn't do the webbing, no need. 
I only did it as insurance because the laminate was an educated guess
There are some photos of it under vacume on the seawind picture area under "this way up"
With a little forethought and planning, building a boat out of polycore may be faster and lighter than strip.
My load test was to have two grown men jump up and down and see how much it would flex. It passed the test easily.
The guy at polycore was great to me and easy to deal with. Best advice I can give is to try it yourself. Its cheap enough
Marty's latest project!
A Polycore Dinghy.
Marty Still sent in these pictures of what he calls  his Polycrapper, his version of a composting toilet.

In the beginning god made man then!
   Marty made this!!                      Ready to install!                               Installed!!                           Final product !
                                                                                                                                           I wonder if Marty is in there?