Brian, what about
Brian, there is a tremendous amount of difference between the manufacture of a cored hull and a solid glass hull, and the repair of each. Not being a fiberglass guy, nor an engineer, nor an expert in any boat manufacturing process, I could see it being less expensive to manufacture a cored hull than it is a solid one, being as resin is very expensive. Manufacturing cost was not the initial question. If you were to knock a small hole in a cored hull, how to you know how much moisture is between the laminate and the glass. Do you just ignore that possibility and slap some glass on, or do you start cutting it back till you are sure it is solid. Do you have to check with a moisture meter to find out. I have seen a foam cored deck that was damaged in a collision, and delaminated, not from moisture but from impact. It was not a pretty sight, and the damaged boat was sent back to the manufacturer to repair. And this was a deck. I'll stick to my origional statement that repair on a cored hull is more expensive, unless someone with some real expertise convinces me differently.