CarbonCore Lightweight Veneer panels are an ideal way to save weight for your yacht cabinets.
The heart of this laminated panel is the same CarbonCore polypropylene honeycomb, that yacht builders have trusted to give them years of tough, rot proof service, that they have learned to expect. These lightweight panels come in thicknesses that mock the plywood that you are used to using, so the geometry of the cabinets does not change.
Cabinet joints can be accomplished by several methods.
Cut a dado through the core, but not through the back veneer, the full thickness of the finished CarbonCore panel.
Brush in thickened epoxy, and insert panel into groove. See figure 2.
Another method of fixing shelves or bulkheads is by attaching a spline with epoxy then dado the core from the adjoining panel the depth of the spline, brush in thickened epoxy and slip the panel over the spline. (See figure 3 & 4)
An outside corner, can be accomplished much the same way, only you will rabbit the edge of one laminated panel (Figure 5) and apply thickened epoxy into the rabbit, and clamp in adjoining piece, (Figure 6)
To join two lightweight panels edge to edge, dado both panels the thickness of the core, brush in thickened epoxy and insert a spline. (See figure 7)
If a radius is required, kerf the panel at the starting point of the radius. Clamp the panel to a flat surface and raise the loose end until the kerf is closed. Measure the distance between the raised portion and the surface of the bench, at the desired radius. If the radius is to be 3 inches then measure 3 inches from the kerf then measure the distance the raised portion is off the bench. This is the distance between saw kerfs. Spread thickened epoxy into the kerfs and bend to the radius desired. Squeegee off the excess epoxy from the back of the laminated panel.
Cutting a dado into a solid frame, and gluing the CarbonCore panel into the dado can accomplish door frames. There is no special treatment to the panel. (See figure 11)
A door can be hung in the frame by one of two methods. Dado the core out of the edge of the panel, brush in thickened epoxy and insert the spline. (See figure 12 &13) Then attach the hinge as normal and hang the door. (See figure 14)
You can also make a frame for the door as in figure 15, and hang as normal.
Countertops and table tops, or shelf edges can be accomplished by cutting your edge molding to the desired shape and brushing in epoxy then bonding it to the laminated panel. (See figure 16)
When using a cored panel, careful planning will eliminate problems encountered once the cabinet is assembled.
There is very little extra time involved but the end result will be a very strong and lightweight cabinet.