[quote=martin_langhoff]I think your plan is sound. Some quick notes/recommendations
* use peel ply for interim finishes and for the final finish both internal (for ease of later repair) and external (for better bonding)
* there's a technique on the external finish (sand lightly, wash w water) so that gelcoat bonds well, this is to remove unused amines from epoxy that might mess up gelcoat cure
* use biaxial or dual bias (stitched) CF for max torsional stiffness w minimum weight
* plan your "scarfing"/taper on the points where material changes; abrupt changes in stiffness will create the next cracking & breaking point
* for the "work window" you've opened, plan to do both scarfing and some stringer or side flaps on the inside; needs support when a heavy crew steps right there...
I don't quite follow why you'd add foam; might be just my ignorance.[/quote]
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