So I was thinking, what it we got woven nylon material and basically melted and pressed multiple layers of the material into a single sheet to use for abrasion resistance. Nylon is ease to melt and so my idea was to put 3 layers of nylon sailcloth together, heat them up past melting point and squeeze them together under high pressure (maybe through a roller). Add to this on one side some woven fibre-glass to create a face that will improve the (mechanical) bonding. Ideally the result is a uniformly thin sheet of nylon with the pores closed (melted) and one side that would offer a good mechanical bond. This would all be done seperately to th laying the board up so it would go into the normal lay up cold.
I wouldn't be heat bonding the nylon to the board, the nylon stack would be set and cold before it went into the layup.
I hope this helps clear up what I'm on about.
i get it.
I'm the last person that should be trying to talk someone out of a "science project" so i won't try here.
But let me add my vote to the growing list of folks that suggest trying this out on a smaller scale before you commit to a lot of time and tears.
Before you give up on bonding nylon sheet stock directly, you may want to consider another experiment.
There are many references to 'flame treating' nylon that has been shown to improve bond strength.
it is easy and has worked for me, but i still dont understand the mechanism well enough to sort out the magic requirements from the part thats just voodoo.
also, desipte the fact that i an a big fan of epoxy and generally resist adding too many ingredients to the mix.... I do have a fair amount of experience with something called Plastic Welder II as an adhesive for bonding Nylon. Its some sort of acryllic advesive. With good surface prep and their primer you can get bonds in excess of 1000 psi shear ( i think) that were always better than comparable epoxy bonds to Nylon.
1000 psi should be good enough for a thin sacrificial layer on the bottom of a board.
especialy considering how many square inches are involved.
on the other hand, a few coats of paint from time to time works well too.
its only water we're dealing with.