Hello Proscience (or Proscience parent?),
First of all, congratulations! I'm glad your project turned out so well! I will happily help you mold your project to better fit the format/guidelines of the county science fair.
What is the name of the national science fair your county fair is affiliated with? There are several fairs, each of which has their own "flavor" (i.e., formats, judging guidelines, etc.). If I know which national fair your fair is affiliated with, I'll have a better idea of how to help you tailor the project.
Also, how long do you have between now and the county fair?
One thing to remember is that science fair projects include both science experiments and engineering projects. The engineering category will be perfect for your project.
Engineering projects usually don't follow the standard scientific method (ask a question, do background research, make a hypothesis, design an experiment, do the experiment, analyze data, and decide if the data support your hypothesis). Engineers use a different process, the engineering design process. This involves defining a problem to be solved or a need to be filled. Engineers then identify specific design criteria, brainstorm different ways they could solve the problem, build and test one solution, and redesign and retest based on what they learn from the previous test. This process repeats (or "iterates") until the design criteria are met. Take a look at these Science Buddies articles to get a better handle on the engineering design process:http://www.sciencebuddies.org/engineeri ... thod.shtmlhttp://www.sciencebuddies.org/science-f ... uide.shtml
When I'm evaluating a science fair project (either an experiment or an engineering project), I'm looking for both process and product. By "process", I mean the process the student used to do their project. Did they follow the scientific method or engineering design process (whichever one is applicable for that project)? Did they thoroughly documenting their thinking with a lab notebook? Did they logically (and creatively) respond to challenges? By "product", I mean the end result - the conclusion drawn from the experiment or the engineered product. Is it innovative? Does the student understand what their results mean or what their product can do?, etc.
As you put together a display board, you want to highlight both the process you went through (the planning, building, testing, redesigning and retesting, etc.) and the end result (your new material). Think of it as telling the story of your project from beginning to end, making sure the cool end result is readily seen. You want the board to read like a newspaper article - left to right, top to bottom - so that people can follow your thought process. The board from an engineering project may look somewhat different from the board for a science experiment project because the two projects followed two different processes.
In terms of data - without knowing the rules of the science fair, I can't say if you absolutely must have three trials of shear test data. If the fair will disqualify you for not having three sets of data, then you'll have to decide how to proceed. The more data you have, the better. But, time and cost are always factors. At this point, you have two sets of shear test data, correct? There may be ways to get more data without having to build an entirely new version of the material.
You should definitely include all of your data, qualitative or quantitative. It is ALL data, and it ALL helps you evaluate your material.
Happy to help!