IMHO a 2 mm thick (Even a 1,5 mm ) solid carbon/kevlar mixed panel/flor plate will outperform the original 1 mm aluminum, it will certainly be just as stiff, provided that you lay up with some of the CF/kevlar at 45 deg .
(or buy some of the cheap biaxial that EC has on sale .. great stuff .. )

a 2 mm Infused CF panel will use about 8 layers of 200 gsm CF cloth -- I would go for 2 -3 layers of "outside"  in the pattern you want and then 2 layers of 300 gsm biaxial -- That will certainly be just as strong as a 1 mm alu plate ..

"Sapere Aude"... Dare to KNOW!

The written word is the only truly efficient vehicle for transmitting a complex concept from mind to mind...

103% of all people do not understand statistics...

Do not adjust our mind, theres a fault in reality :-)

Just re-read your original post - why would you bother with a core on a 2mm thick floor panel? If you want to then maybe use corecork rather than a thin foam.

Use a nice stiff foam, it will help with sound dampening, whereas a honeycomb won't. It's also easy to shape with a knife/saw/sandpaper/sander/tablesaw etc... 

Thanks for that Rob

Is it easy to create an angle when using a honeycomb core?




Not having worked with it previously, I'm not certain what to expect when trimming or cutting it, especially the Nomex variant?

Have the core/foam undersize and 45 the edge so in the areas where it is under a chassis rail both laminated meet and you only mount through solid carbon

I'm thinking of replacing the floor panels on my kit car with carbon ones.