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polyurethane sheets
Richard,
I've used polyurethane sheet, that I got from a local GRP fabricators (FiberForm, Lancaster). It works easily, can be made into blocks by layering it with resin and takes a glass-fibre skin well. Problem is that it absorbs a lot of resin and the part ends up rather heavier than you would wish. I've no experience with it and carbon-fibre or kevlar, or an autoclave.
I've had more success using paper honeycomb (Dufaylite), as alloy honeycomb is out of my budget range. 'Glue' the honeycomb to the skin with polyurethane foam - the type used by house builders for filling voids, comes in an aerosol. Saloon roof 9kgs, Doors 5kgs each.
John
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