I'd echo the recommendation to *not* use expandable foam in a core repair. The characteristics of the material may seem similar to end-grain balsa but crush resistance is very different, and additionally it is difficult to get thicknesses, densities and full-surface bonding "right".
As an alternative to balsa, there are a bunch of synthetic core materials out there (klegecell, divinycell, etc). I don't know if there are downsides to using a synthetic material in an otherwise balsa-cored deck, but I do know that the engineered core materials are [generally] easier to form around complex curves (including thermo-forming and vacuum-bagging) and [generally] don't create so many voids that need to be filled when shaped that way. ymmv Bruce _______________________________________________ Email address: CnC-List@cnc-list.com To change your list preferences, including unsubscribing -- go to the bottom of page at: http://cnc-list.com/mailman/listinfo/cnc-list_cnc-list.com
