How much heavier would it be compared to the aluminum?
According to (you guessed it
) Boatbuilding with Plywood
by Glen L. Witt, Douglas Fir plywood would have the following weights :
Thickness / Weight lbs per sq ft / Weight with fiberglass
1/4” (6mm) / .80 / .92
5/16”(7mm) /.95 / 1.07
3/8” (9mm) / 1.13 / 1.25
Click on the link below to see Aluminum sheet weights :
If you go with the plywood/fiberglass, corners can be molded to any contour desired. Stitch & Glue techniques can also be used in the corners to save weight as additional framing members won’t be needed. You can also substitute thin plywood veneer, PVC foam or fiberglass screen as the core or have no core at all. Click here
to see how we built a ‘coreless’ driveline cover.
Good luck with your project and post any progress !
Edits : Fixed broken link
Paul Kane Chelsea, PQ
Building the Glen-L Hot Rod