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Author Topic:   Repair Black Wet Foam
jay posted 03-11-2002 07:15 PM ET (US)   Profile for jay  
Trying to do a repair right, so I need some help.

I'm remounting the oil resevoir to the deck of my '86 Newport. I ground out the fiberglass around the original screw holes, found about 1 inch deep and 1 inch in diameter of black wet foam. I ground all this out.

Now my question. The foam near the underside of the deck is beige from 1/8 to 3/16" under the glass. Is this foam wet too? Do I need to keep grinding? I'm up to about 3.5 inches from the original screw hole, and I'm still finding this beige foam. Could this beige just resin from the deck that impregnated the foam?

I hate the thought of having to fix a screw hole by grinding away 12 inches of deck.

If this beige is water damage, can I just let the boat sit in the sun a couple of days to dry out, or do I have to grind?

Tom W Clark posted 03-11-2002 07:23 PM ET (US)     Profile for Tom W Clark  Send Email to Tom W Clark     

I'm not sure I follow you. You have now created holes that are 1" in diameter?

The black foam you describe as black. I presume this is from the fastener staining the adjacent wet foam. Is there no plywood backing in this area?

The foam should be beige or white. If you found wet foam then I suspect there is some water in there and based on the CSW experiments I suggest you vacuum as much of the water out as possible and then make the repair.

I hope you are going to put the oil reservoir in a battery box this time.

whalerron posted 03-11-2002 10:37 PM ET (US)     Profile for whalerron  Send Email to whalerron     
Put the oil tank in a battery box? My Johnson dealer suggested this too for my 1.8 gallon OMC oil tank. That tank is about as long as a group 24 battery but it is much wider than a group 24 and I have yet to find a battery box it will fit in. Is there some other box out there other than a group 24 or a group 27 box?

(Length here is the longest dimension of the battery footprint and width is the shortest dimesion of that footprint)

- Ron

Tom W Clark posted 03-11-2002 11:15 PM ET (US)     Profile for Tom W Clark  Send Email to Tom W Clark     

I donít know what tank you have but the three Johnson VRO tanks I had fit quite nicely into a standard group 24 battery box like the ubiquitous Tempo black plastic model.

The width was a snug fit (no slop at all) the length provided about an extra 1/2" to 3/4" which came in handy for stowing the coiled up extra wire from the VRO sender.

Perhaps OMC has changed the dimensions of the VRO tank but I had always assumed they made it the size they did precisely to fit a standard battery box. To make it too fat to fit a standard battery box seems foolish.

Have you actually tried to drop your tank into a battery box?

whalerron posted 03-12-2002 08:19 AM ET (US)     Profile for whalerron  Send Email to whalerron     

Yup. That new OMC 1.8 gallon tank will not fit in a battery box. What was the capacity of the other VRO tanks you had? Maybe they are smaller in both capacity and size.

- ron

jay posted 03-12-2002 06:51 PM ET (US)     Profile for jay    
Tom,thanks for the help.

I now have two holes in the glass deck, about 6"-7" in diameter each. The center of the hole is where the original screw was. I have two holes in the foam that measure 2" in diameter each and 2" in depth. From the outer edge of each foam hole, I slope upward toward the glass deck.

I kept grinding the deck because I kept running into beige foam. I still see beige foam. Am I grinding too far? Is the beige foam okay to leave?

The black foam was pitch black and wet to the touch. I knew all of the black had to go?

What's the advantage of using the battery box?

vdbgroup posted 03-12-2002 10:12 PM ET (US)     Profile for vdbgroup  Send Email to vdbgroup     
You are right. You need professional help?
jay posted 03-15-2002 06:24 PM ET (US)     Profile for jay    
Girlfriend tells me I need professional mental help, but I think that's only because I'm spending more time with the Whaler than her.

I would like to finish the repair myself. Still would appreciate any advice/suggestions.

joem posted 03-18-2002 06:24 AM ET (US)     Profile for joem  Send Email to joem     
It is not a big deal cut out all the wet foam that you can. Get the 2 part foam system pour it into the cavity let it harden, sand it, then do the fiberglass repair it really isn't hat hard. You just need to get through the first repair then it will be alright.


Tom W Clark posted 03-18-2002 01:19 PM ET (US)     Profile for Tom W Clark  Send Email to Tom W Clark     

Stop chasing the beige foam! You will be left with nothing if you keep going. Patch it up as best you can.

whalerron, I'm not sure exactly what the capacity of my tanks were but It was something like 1.6 or 1.8 gallons. Perhaps the design changed.

The benefits of a battery box for the oil tank are:

It is effective in holding it down.

It will contain an oil spill or oil leak if there is one.

It holds the extra wire coming from the tank.

It keeps sunlight, dirt and salt spray off the tank and also protects it to a degree from getting banged up and damaged.

It looks better and matches the battery.

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