Is it possible to mechanically shave down nomex honeycomb thickness to meet a certain profile?
How do you shape core for a wing profile? If honeycomb is not possible or feasible to profile the shape what is?
Also how many layers and weight/oz of cf are needed for a small 60" flight control surface on a wing?
How heavy per cubic foot is this core?
Yes, absolutely possible. Can also be done with foam cores. I have posted this before, but included a pic of aluminum honeycomb being machined to a specific profile. Have posted others of nomex as well, but coincidentally this is part of a wing. 
As for the rest, more testing and fewer questions. Yes this is a discussion forum, but people need to do some research on their own as well and not wait for others to give them hard-earned answers on a silver platter. 
Here’s another pic of Nomex milled to shape. Process was just started, no taper yet. It’s also for a wing. Note the various densities bonded together.
Do you plan to this by hand or…?
Yes.
Special core tools, normally done on a mill, but if you need a simple bevel, you can use a palm/disk sander. Core knives help rough shape.
Weight all depends on what core. I believe the units for the products are normally done in PSF (pounds square foot), or a general cubic density measurment. Again, all depends on everything. Cell size, thickness, core material, etc.
I won’t touch questions about planes, since that is a field upon itself, and if done wrong, will be BAD.
TET, stiffer densities on the outer layers of that nomex honeycomb wing core? lol.
I may end up not needing core but i wanted to price it with and without. The drawing doesn’t call for core but i wanted to price it as an option if they can fit it into their design.
I hear ya on testing.
TET what are you using to bond the different densities together (the white lines visable in the pics)
Higher densities in areas of greater load and hinge/mounting points.
It is a foaming film adhesive cured in the autoclaves.
If anyone has any questions about machining nomex don’t hesitate to ask. I’m a sales engineer for EURO-COMPOSITES Corporation. We manufacture and machine aramid and para-aramid fiber honeycomb for the aerospace industry. If I can figure out how to post some pics of core being machined, I would. Can you insert images here or do they have to be a link?
You should be able to insert images. There’s an attachment button to put content directly on the forums. You can also use outside images but your posts might be filtered initially.
Whats the hold down method employed on the nomex honeycomb in the pic? The aluminum looks like it is bonded to one skin and then machined, is the nomex bonded to a single ply and held with vacuum? Or another method?
Thanks,
Mike
Correct.