Thread subject: Whaler Central - Boston Whaler Boat Information and Photos :: Wet Foam - what to do?

Posted by Binkie on 07/09/13 - 7:39 AM
#27

Kamie, here is an idea I just had. Mtown hit on a good idea with a long sawzall blade. I think a electric carving knife would be easier to use. I used one several times to cut up large pieces of dense foam for cushions. It cuts foam like butter and does a nice neat job, so there in no reason it would not work for removing foam in your boat. I bought mine at Target for about $10. I don't use it to carve roasts or turkey, but then I don't eat that stuff anyway. You say the wet foam is in the mid to rear portion of the boat. Cut 12"x12" squares out of your deck. You should have about 12" between these cutouts. Cut them out with your circular saw set on 45 degrees inward. Number these cutouts and also draw an arrow pointing forward. the idea is your going to replace them as you foam the deck. The whole premise here is that the deck is not rotted and is worth reusing. The 13 footer due to is its convex shape is not plywood based. Now it should be easy to clean out the foam with your carving knife. OK, next pick up a concrete block for each square hole you cut. Use the right type of foam, I think 4 pound, but you can reaserch this and buy the foam, . Now start foaming toward the front and work towards the rear. Pour the foam in through the square holes, (you will have to practice to get the right amount, but when you think you have enough replace the cutout and put a conctret block on top. they weigh about 40 lbs, and should hold the cutout down. The 45 degree cut you made will keep them from falling into the foam. Just keep at it until you get them all filled. The foam will stick the cutouts down, so they just need to be glassed in. then glass over the whole area with glass mat.

This idea popped into my head a little while ago while I'm out in my garage laminating the center console mold I'm building. So I'm typng this on a break. Hope it helps. Mtowns idea got me thinking.