I'm making good progress on the hovercraft. With the help of Michael I filled in the center of the plywood on the first side. The biggest update to the process was to do it not in full sunlight and use more boards for holding down the plywood. The 12-18" gaps between weights was enough for the 1/8th inch plywood to flex noteably.
The following night I had some time to finish up the side. I tried sawing on the saw horses since the hovercraft was in the way of the pallet. I used the angle iron to make a fence to run the saw along instead of drawing the line. However the flexible board bowed enough that the saw couldn't follow the fence(it drifted under the fence). So the cut was not exactly straight. You'll see the door close. As it was late at night I closed the door when sawing so that I wouldn't be too loud for the neighbors.
The next round of work encompassed cutting all the plywood for the second side. Again I was cutting with the door closed, but I moved back to cutting on the pallet. The plywood still twisted enough to jam the saw once I was 6' into the 8' cut so I finished the cut coming from the other side. I need to prop up the outside edge too. I was going to glue it all down too, but on inspection I noticed that I was getting close to the bottom of my epoxy supply so i decided not to continue and find out that I was half way through gluing and didn't have enough epoxy. More's on order and should be here soon.
I'm going to need to rip plywood edges to go around the perimeter which will be pretty narrow. This will definitely require a proper fence as they will be narrow strips. Or a table saw would be optimal.
I also have ordered a furniture dolly to help me manuver the hovercraft around the garage. It's now heavy enough i had to get help moving it by myself. I could lift it, but it's so awkwardly big that it's impossible to move without dragging or skuffing. And the foam is still quite exposed.
