Method of making a hardcore honeycomb panel and honeycomb panel made thereby

A method of making a hardcore panel comprising the steps of providing a stack of predetermined width comprising a first plurality of parallel substantially uniform first width planar boards of grained lumber and a second plurality of parallel planar boards of grained lumber having a second substantially uniform width less than said first width with said first and second plurality of boards being fastened together and arranged in said stack in step-wise fashion in a plurality of levels with said first width being substantially equivalent to said stack width, said stack having opposed top and bottom parallel faces, opposed front and rear faces and a pair of opposed parallel side faces, with the top and bottom faces and side faces being substantially planar and the front and rear faces being stepped from said bottom to said top face, said first width planar boards comprising said bottom and said top faces of said stack, said bottom face comprising the bottom level of said stack and said top face comprising the top level of said stack with said second plurality of planar boards being arranged in alternate levels with said first plurality of boards in said stack and with each of said alternate levels comprised of said second plurality of boards being comprised of at least a pair of substantially uniformly spaced apart second width planar boards forming a longitudinally extending channel in said stack;

• initially completely cutting said stepped stack along a first cut line through said faces from said face to side face at a predetermined acute angle between said first cut line and said bottom face to provide a substantially planar front face normal to said first cut line, said front face being sloped between said parallel planar top and bottom faces at said acute angle with respect to the plane of said bottom face;
• completely cutting said initially cut stepped stack at a predetermined distance from said first cut line along said side face along a second cut line through said side faces from side face to side face at said predetermined acute angle between said second cut line and said bottom face to provide a first cut portion from said stepped stack having a substantially planar rear face for said first cut portion normal to said second cut line, said first cut portion front and rear faces being parallel completely cutting said first cut portion through said first cut portion front face from said first cut portion front face to said first cut portion rear face along a third cut line normal to said bottom face to provide a first plurality of substantially identical cut segments each having said first cut portion sloping front and rear faces and whose top, front, bottom and rear faces are rectangular and whose side faces are rhomboidal, each of said first plurality of cut segments comprising said stack between said top and bottom faces with the top and bottom faces of each board in said stack being parallel to said cut segment top and bottom faces;
• and fastening said cut segments together with said front faces in a common plane with alternate adjacent fastened segments being rotated 180.degree. about a longitudinal axis through the center of said segment parallel to said front face slope to provide a top and bottom surface for said fastened segments comprising alternating inverted sloping surfaces of said segment top and bottom faces whose slope is at an angle supplementary to said acute angle to provide said panel with a portion of said sloping surfaces defining sloping channels in said panel, whereby a honeycomb hardwood panel is provided.