Boy, have I got the perfect material for you, there's a company in Miami call Poly-u-mac, they sell a product called Gatorboard, is like a foam sandwidched in between fiberglass, extremely light but very strong. I reinforced the stringers next to the gas tank with it, 1 1/2 I used. Very easy to cut and to work with, I'vee seen a transom made with this material holding 3 300 HP outboards.
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