1" will be fine. Two layers of 400 db/12 oz, one 75mm/3" wide, one 100mm/4".
An alternative to cutting and shutting is to bend the table. Make a couple of full length supports from mdf, then lay the mould table on these, seal the joins and infuse. probably more work than it is worth.
If you do cut and shut, make sure you do the glassing with the roof upside down. Very messy otherwise, especially if you then fair and paint it.
Lots of other ways to do it, including a KSS deck edge radius, although this will need some cuts to get it to bend, but none are quite as simple as a router, glass and fillet. Glass the inside as well.
Our next build will have the join as part of the infusion, similar to the DER, but curved.
rob
I am trying to work out an easy way to join the panels for making the Raider design. I have got it figured out on how to join most of the panels together in flat sections, where I can just overlap a flange that I include when I infuse the panels, but I haven't a good idea on how to deal with the coach roof.
I think I am going to change the design a bit to let the roof be a curve. I think I can do that by making cuts in the 25mm foam panel, like KSS does. This way, I can make the coach roof for each side out of a single 7.5' wide panel. My problem comes when I need to attached it to the topsides. Should I just round the edges of the 25mm panel, and then tape it to the topsides, then fillet the interior join? That seems relatively simple, but I only get a 1" radius on that curve, and I am not sure that will be strong enough.Other ideas?Thanks,- GardnerPasadena, MD