I just repaired a carbon copied Sawyer 17’9” Cruiser
We had done a lousy job laminating the inside, including a barely stuck bottom layer of 1/8” H80. That hull was all polyester resin, I don’t recommend it.
I think I salvaged the build using a bunch of 3/8” H80 that I bought for next to nothing.
Around the dinner table, we have the plan perfected.
1 layer of carbon over the plug, 2 layers 6 oz E glass over that keeping the stems open. All epoxy resin.
Flip the hull, close the stems then add H80 to the football and maybe some ribs. That foam MUST be vacuumed in place. Finish the inside with another layer of carbon.
Unless we have or make a female mold, I can’t see any way to support the foam and still have an accurate shape.
1/8” H80 with single layers of 6 oz E glass is more than adequate strength for all but the most abused hulls.
I’ll start a new thread detailing the carbon copy build, subsequent lamination failure and desperate salvage attempt shortly (spoiler alert: I think I saved it)
If I had unlimited resources, I’d build some way to heat form full sheets of 1/8” H80 over a plug, but sadly my pockets are not that deep.