Where to buy Honeycomb panels? - Sprinter-Source.com

Ok Gang, most of you have been around the block a few times and are google experts so I need you're help.. Who knows where to purchase premade Honeycomb panels?...the cheapest I've found is about $.00 US per sheet.

The details are:
-1/2 thick
-nomex core or similar, not aluminum
-fiberglass facing sheets, 2 plies per side minimum
-4'x8'

Why Honeycomb, resists flammability and a significant weight reduction,. also I prefer to work with this.

A thousand bucks is way too much and especially for a Canadian, there must be something cheaper. The last resort and I'm trying to avoid this is too make my own panels but it is time consuming and I have better things to do.

Thanks The Boeing surplus store was for the most part tooling and would not make its way on an aircraft. Parts that are deemed non-conformance in new manufacturing would either be repaired or subject to scrapping per the OEM or MRO QMS. So based on this I will not be able to locate new non conforming material but I can get used. It will be in poor condition, the baggage pit bulkheads will be dented big time and the passenger floors are gross, you know puke, coke etc...not going in my van...

The Boeing surplus store was for the most part tooling and would not make its way on an aircraft..

Let's see.... once i picked up about 60 feet of (hardened) aluminum trailing edge stock, another time i somehow managed to resist a complete front ring of a jet engine nacelle, and one time (when i was looking for one) i found a ping-pong table.

Scads of fabric and velcro from (probably dummied-up) aircraft interiors ...
and, yes, many many drills and other tools.
**sigh** ... i really do miss the facility...

--dick

make my own panels.

Yes! Matt or Pat at Fiberglasssupply.com can help you with the materials/process.

We molded some kiteboards out of HT110 Divinycell that came from Boeing Surplus.
Each sheet has a serial number. Back then we also lucked into a semi-load worth of 2" high grade 4# EPS that I machined and vacuum bagged into some kite surfboards. The material was supposed be used to insulate high end diesel pushers manufactured here in Oregon but the wrong size was shipped. Matt at Fiberglass supply drove their truck down to pick it up for me.

Let's see.... once i picked up about 60 feet of (hardened) aluminum trailing edge stock, another time i somehow managed to resist a complete front ring of a jet engine nacelle, and one time (when i was looking for one) i found a ping-pong table.

Scads of fabric and velcro from (probably dummied-up) aircraft interiors ...
and, yes, many many drills and other tools.
**sigh** ... i really do miss the facility...

--dick

Wow, that is a gold mine and would be awesome, my kind of candy store! I never made it down there but I have a lot of friends who bought tools there over the years.

I was able to work with a company (McStarlite) on a stretch form project that also made the engine lip on the nacelle for 37's. That part is very difficult to manufacture and needs to be perfect, I recently saw someone make a chair from one, looked sweet.
They stretched formed a Convair nose skin for me. I can ask around at work to see if if there are any suppliers in Canada? A lot of our composite stuff for interiors comes out of California through C&D or zodiac.

The issue would be shipping, as a 4x8 sheet is going to be killer on freight. Even if you order 5+ sheets the additional cost per sheet will be noticeable. A lot of suppliers will charge extra for panels with material/burn certs. If you request for panels that are not certified/tested the cost might be less.

If you can find a interiors distributor in Canada, many of them carry Boeing BMS spec blank panels as they are sometimes needed for repairs. I work with these materials for a living in both manufacture and maintenance activities. I managed to find a supplier of aluminum core and skin honeycomb panels. I'll use the 1/2" for the combi bed setup and probally use 1/4" for the Lav, galley and overhead bins.


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I work with these materials for a living in both manufacture and maintenance activities. I managed to find a supplier of aluminum core and skin honeycomb panels. I'll use the 1/2" for the combi bed setup and probally use 1/4" for the Lav, galley and overhead bins.


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Oh thats definitely good to hear. I'm very excited to see what you put together. I was originally wanting to go that route but knowing what kind of skill is involved I decided to leave the cutting and kerfing etc to the pros.

I also thought about vacuum forming some Kydex for various parts... but in the end my build will probably be slightly more amateur. Just curious.

Are you using the Hexcel Fibrelam aircraft flooring product?

My rule of thumb was that 1 lb of weight in the van cost about $5 in fuel to move 200k miles.

I think the airplane fuel calculation is that breakeven for 2 million miles justifies $50/lb material.

Eh, I'm happy to just use a modular furnishings approach that lets me have a daily driver that is many hundreds of lbs lighter than our expeditionary weight.

Dan

Just curious.

Are you using the Hexcel Fibrelam aircraft flooring product?

My rule of thumb was that 1 lb of weight in the van cost about $5 in fuel to move 200k miles.

I think the airplane fuel calculation is that breakeven for 2 million miles justifies $50/lb material.

Eh, I'm happy to just use a modular furnishings approach that lets me have a daily driver that is many hundreds of lbs lighter than our expeditionary weight.

Dan

Hexcel is a premium manufacturer, I would like to use their product but I found something more in my price range. Plascore produce a 1/4" aluminum/aluminum honeycomb sandwich for $187.00 per sheet and 1/2" for $199.00 US. I originally thought glass and paper would be cheaper but it turns out aluminum is the cheapest which I will use.

Another question....Who knows where to buy Tedlar?

Yes! Matt or Pat at Fiberglasssupply.com can help you with the materials/process.

We molded some kiteboards out of HT110 Divinycell that came from Boeing Surplus.
Each sheet has a serial number. Back then we also lucked into a semi-load worth of 2" high grade 4# EPS that I machined and vacuum bagged into some kite surfboards. The material was supposed be used to insulate high end diesel pushers manufactured here in Oregon but the wrong size was shipped. Matt at Fiberglass supply drove their truck down to pick it up for me.

I'm familiar with Fiberglass supply and also I have the experience to produce honeycomb products. I made a hollow honeycomb windsurfer years ago because I could. This time around I don't want to mess with prepregs or a wet layup "Burrito Tech as the phrase was coined in the Gorge I believe... Work is unlimited overtime and so in the long run it makes sense to purchase. Do you know where to purchase tedlar?

One approach is to seek out the "surplus" outlets from industrial users, such as aircraft manufacturers.
(Bombardier for a Canadian example)

--dick (who used to visit Boeing Surplus (when it still existed as a "store"))

Hilarious, Dick. The BSS was the first thing I thought of when I read the OP. I recall seeing sheets of honeycomb aluminum there on several occasions.

Like you, I miss it badly. The best shopping ever. I'd make a run down from Vancouver for the sole purpose of browsing those bins. Some amazing stuff there.

Best thing I ever bought was a block of teflon. Worth a fortune. Cost me ten bucks. Used it for years in ways too numerous to mention. I still have an office chair from there.

Maybe there's one of them in St Louis.

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