A technique for making a honeycomb structure includes bonding a less than totally cured composite skin (16) to a possibly contoured honeycomb core (8). The composite skin (16) comprises fibers and a resin chosen to maximize the strength and stiffness of the skin (16) when cured. Non- contiguous adhesive fillets (5) are prepositioned onto faying surfaces of the honeycomb core (8). The adhesive (5) is preselected, independently of the preselection of the resin, to maximize the strength of the bond between the skin (16) and the core (8).
A thin, lightweight scrim cloth (14) is interposed between the starting skin (16) and the filleted core (8). The scrim cloth (14) prevents resin from flowing into the core (8) and allows a safe place for the intermingling of resin and adhesive (5). The assemblage is heated under pressure, cocuring the adhesive (5) and the resin. The fillets (5) are preferably prepositioned on surfaces (10) by means of applying an adhesive-coated fabric to the faying surface, heating the fabric-covered core (8) so that some of the adhesive (5) flows out of the fabric (1) and into the core (8) at a region near the faying surface, cooling the core (8) so that the only substance remaining adhered to the core edges (10) is the adhesive fillets (5).