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  What type of expanding foam to use iin rebuilding an old 16' whaler?

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Author Topic:   What type of expanding foam to use iin rebuilding an old 16' whaler?
David Livingstone posted 10-20-2000 11:41 PM ET (US)   Profile for David Livingstone   Send Email to David Livingstone  
Just bought another old whaler that was used as a dive tender. The owner has removed the floor and foam and tossed both in the garbage. The inner bow, sides and transom are still in tack (to a point). Can anyone give me advise on installing a floor and foam
in this pre 1972 hull. I downloaded the diagram from Classic Whaler for locating fastening wood in a 16 1/2 Boston Whaler. I already have a 1983 15' cc whaler that I saved in 1998. It had a shotgun hole in the bow (hunting sea ducks), a 3" hot in the bottom and alot of epoxy, but she looks and runs great today. I had to turn down buying a 22' Revenge because the family (and me) couldn't part with this little boat to help finance the 22' footer. Thanks in advance for any help you can give me, David.
DIVE 1 posted 10-21-2000 08:28 AM ET (US)     Profile for DIVE 1    
On a BW the foam is the structure wrapped in a thin layer of fiberglass. You must keep this in mind when you replace major sections of foam and glass. You will not be able to duplicate the factory foam technique(compressed and very rigid). If you put in a new floor and pour in expanding foam, the bottom of the hull will crack with usage due to the low density of pour in foam. The only way to save the hull is to strengthen the existing fiberglass in the bottom of the hull first and then proceed with the new floor.
We are working on a 13 in which the entire inner hull was removed. We ground the entire inside of the outer hull and layed 2 layers of biaxial matting with vinylester resin. This replaced the strength of the factory foam. The easiest way to lay the floor is with 1/4" plywood shaped and bent to fit. Cover plywood with vinylester resin, a layer of biaxial matting followed by a layer of 6oz. cloth.
To refoam the core, stand the hull up on the transom. Drill 2" holes in the new floor, staggering from side to side and top to bottom. Holes should be 2'-3' apart. Start at the bottom holes and pour in a little expanding foam. Let the foam expand and solidify, add more if needed or move up to the next hole. The key is to fill the entire hull. Some foam should expand out of each hole before proceeding up to the next hole. When the entire hull is full, cut off excess foam from the holes and refiberglass the holes shut. Now you can sand and finish the floor.
Have some patience, this is a long slow process.

For vinylester resin and foam try

bigz posted 10-21-2000 10:26 AM ET (US)     Profile for bigz    
David -- Dive 1 makes a good point on reinforcing the existing inter hull prior to foaming and installing the deck -- another source for foam -- might be a little more costly but definitely easier to use is this outfit ---


David Livingstone posted 10-21-2000 11:33 AM ET (US)     Profile for David Livingstone  Send Email to David Livingstone     
Thanks for your info. I did notice that the outer hull was thin and I'll add more glass to the inside before proceeding with the floor. The previous owner did put some glass on, but there are still weak points. Just a note, he had 5/8 rope tied to the lift eyes and was still using the hull for pouring cement around wharf construction?
Thanks again, David

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