1/ Say, if I sent you AutoCADD drawings/dimensions would you quote on cutting the molds for my hatches? (foam would be cheap to ship too)
We can take a look at it and see if it makes sense. If it cut files can be made fairly simply, then I do not see why not. Send me a sample of what you have in mind.
2/ Do you mind sharing the schedule you used? I saw you mention 2 X 1708... I was planning on 2 X 1708 with 1/2 H80 for most of the middle are to help prevent flex.... is that what yours was in the picture with the H80?
I was going for thickness, about 3/16" single skin around the lip. I used scrap glass for this, but I used mostly 1708 and db1200, db1700 because they can be moved into different directions without puckering. Inside and outside skins are about 1/8" each. The core I used was 2 x 1/2" divinycell, again i used what scrap I had around, it could have been nida core or plywood too.