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Old 11-26-2015, 11:05 AM   #1
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Kerfkore for panels

We want to upgrade some of the flat panels in the cabinetry of our 2015 25B. For the sake of not adding weight we were thinking of using a Kerfkore material. Has anyone had any experience with this material.
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Old 11-26-2015, 03:20 PM   #2
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I've used similar products in the past as a television set designer. There are rigid foam panels with either a paper facing or a plastic facing available. The plastic is pretty puncture resistant, the paper isn't. The biggest issue with panels like this is the edges, which are pretty easily mangled, so you have to reinforce those. While they're really lightweight, they won't have the durability of the walls that a typical RV has, what's known as a torsion box and isn't much more work than using foam core panels and reinforcing the edges (it's the way Ikea makes shelves). You build a torsion box by constructing a wooden frame and then gluing thin panels (luan) to the face and back. Often RV manufacturers will just glue the luan to the face for economy, although it lessens the structural integrity of the finished panels.

If Kerfkore has heavier duty facings than other foam panel products, it would work for walls although you'd still have to figure out a way to construct corners. There is probably an existing system for doing this but I don't know where you would find it.
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Old 11-27-2015, 07:28 AM   #3
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I was planning to use it on the face panels for the interior furniture. Yes, they do offer hardwood veneer laminates which are used in high end boat construction of interior furniture.
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Old 11-27-2015, 01:50 PM   #4
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I did a web search for Kerfkore and it is panels with kerf cuts on one side to allow for bending along curves. Probably not what you want to use, which is Foamcore/Foamkore panels with 1/8" luan or plywood facing. Foamkore panels are available with an optional internal edge band that can allow for more conventional assembly construction methods. -- Kerfkore Company | Foamkore - Lightweight composite wood panels.

I think if you can get the panels to build with, you've hit upon a very good idea.
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