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Message: <blockquote data-quote="thill" data-source="post: 518523" data-attributes="member: 4972">I would skin the area on the outside with aluminum.  Bed it in epoxy, is what I would do.For the core, I recommend against using Azek or other PVC boards, unless you have the tiniest little motor on the back.  They are soft and rubbery, and will flex and take a "set" if weight is applied over time.    Your transom will end up sagged out unless the brace helps enough to hold it straight.Use a double-layer of plywood, or you can use a stack of 2x8 in Southern Yellow Pine (SYP) glued and sealed together with a skin on the inside, if you simply don't want to deal with plywood.There are many ways to skin a cat, but how you go about it will determine what kind of cat it will be.</blockquote>