I posted this on the Flexifoil forum thread on ply board building in reply to a couple of questions, but I'm posting it here too because it covers some details I meant to mention:
I've just stuck two battens of a suitable height to the floor (to give me the rocker), covered it all with a polythene dust sheet, put the laminated board on top, then covered the board with the dust sheet and then put the weights (bricks) on top. The majority of the weight from the bricks is placed at the point where I intend the outer footstrap bolts to go, this way I'll get a gentle progressive, almost eliptical rocker. I've used the poly sheet before in a test and it provides a cheap, perfect and very thin protective layer to stop the epoxy sticking where it shouldn't.
I did lightly brush (or rather spread) some epoxy on all ply contact surfaces before adding the epoxy/silica mix, so hopefully it'll bond well. The only bummer is that halfway through the process, my one-pump system started acting up, so I had to estimate the volumes of hardener & resin towards the end. I was doing so well, it'd be a bummer if the whole thing was messed up by faulty measuring pumps. I have a feeling it's going to be ok.
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