Sandwich composites based on coir fiber nonwoven mats as core material were manufactured by Vacuum Assisted Resin Transfer Molding technique. Mechanical and physical properties of produced coir/polyester and coir‐glass/polyester composites were assessed. Samples were evaluated according to their reinforcement contents, resin contents, areal density, and thickness. Tests on physical properties revealed that coir‐glass/polyester sandwich structure has the lowest values of thickness swelling, water absorption and moisture contents compared with coir/polyester composite. Mechanical tests such as tensile strength, open‐hole tensile strength, and flexural strength were also performed on all samples. Coir‐glass/polyester sandwich structure showed significant increase in tensile strength of 70 MPa compared with 8 MPa of coir/polyester composite. Introducing two skins of fiber glass woven roving to coir/polyester increased its flexural strength from 31.8 to 131.8 MPa for coir‐glass/polyester. POLYM. COMPOS., 38:2212–2220, 2017. © 2015 Society of Plastics Engineers