: You know Bill, it's not nice to keep such useful information to
: one's self! Share with the group.

Ok, frames:

I use backer rod, it's a closed cell foam rod used for keeping caulk from falling into deep cracks. Most building supply places carry it and it's available cheap in huge rolls online. Again like the waxed paper the epoxy doesn't stick to it very well but it does stick.

I make an undersized frame template out of cheap plywood. I layer a piece of cheap 1/4" ply on the outsides of each side that is slightly larger than the template (makes a semi-rounded edge to keep the foam rod from rolling off). Then measure the circumference of the frame, cut the backer rod to that length (a little long isn't a bad idea) and it cuts very easily with a razor. Then pull the sleeve onto it, the same thing as the long tubes a slightly thinner tube (doesn't have to be foam) works well as a feeder. Then just roll the sleeve over the foam around the template and tape the ends in place. Ends should be touching if possible. Then apply the resin to the outside 1/2 of the cloth and once set up remove from the template. It'll be somewhat rigid with only half the sleeve coated. Then slide a piece of sleeve over the joint and epoxy it and the inside of the frame. Once hardened you've got a seriously light weight frame that's foam filled.

Now I'm working on the joints, have some ideas but will wait till I have all the parts made.

Oh yeah coaming, next installment.

Bill H.