I am building a buoy... Need your help

[momo3]

Hello guys, I am new here. I am not building a boat, but I thought you could help.

I am making a buoy prototype. I made it out of foam, but wanted to make it more durable. So I covered the foam with gesso, and then fiberglass. I used Bondo automotive fiberglass sheets that were very thin and fabric like. I then used "Water Puddy" to smudge across the buoy to smoothen it out and to fill in the gaps. My creation was looking like paper mache (many bumps, etc.), but has improved with the water puddy. I am now sanding it down, and wish to paint it.

I was just wondering - how is my process so far? Have I messed up? If so, how can I fix?

And the most important question - what kind of paint should I use ? I want something durable and thick (to even out bumps). I was thinking latex. But would that peel off? Could I use latex and coat it with something?

(Polyester resin and fiberglass turned into a huge disaster for me. I worked in my underwear and found that the microscopic fiberglass embedded in my legs doesn't feel to hot. Quite itchy - Ive been doing the fiberglass jig for days. )

[Toot]

As long as it floats, you did fine. The fiberglass will hold whatever is inside it in shape. But I would have suggested the following-

Make the foam shape. Cover it with a slurry, mixture, of epoxy and microballoons (I think some boat people use epoxy and flour? But I dunno...). Coat the foam with the slurry. Then use the epoxy and fiberglass cloth. I might then use Bondo to fill in the small gaps and even things out. You could also use slurry for that, but it's a lot harder to sand. I don't know what Water Puddy is... can somebody clue me in? I would have just used Bondo for that, given that it's just a Buoy.

As for the gesso, that's interesting. I have no idea how that would work. I assume you are using a foam which is dissolved by the vinylester resins and that's the reason for it? You could've just used a cheap epoxy instead and saved yourself some pioneering.

I can't help with the paint though.. I'm not a boat guy.


Anyway though, like I said, if it floats, then you did good.


Don't worry about the itchiness. It goes away after a day or so. If you are careful, you *can* work in your underwear, but you have to handle the fiberglass gently if you do so. I don't even notice itchiness anymore... however, I've found that fiberglass splinters are par for the course. The only time I really worry about shielding my skin is when I'm doing mechanical grinding... or working with resins which can be made up of some nasty stuff.

[momo3]

Thanks toot!

Yes I used the gesso to prevent the polyester resin from eating the foam.

[momo3]

When you say bondo, do you mean the bonda filler stuff ?I have been thinking of picking that up. Smoothing this out is quite fun. I just picked up some liquid nails (because I went through my "water puddy" and the hardware store was closed) to fill in the gaps with. But I may try the bondo filler stuff tmw.

[Toot]

I can't say for certain that this would work.. but if I was trying to do this on a budget and was willing to experiment a bit, for convenience of acquiring materials, I might be tempted to try something like this...

1. Make the foam core.

2. Spray it with one of the following- a can of epoxy spraypaint, or a spraycan of "rhino liner" or other rubbery-type of item found at the autoparts store.

(I'd bet either of those would be sufficient to allow you to use a vinylester resin on top... but I can't speak from experience there)

3. 2 layers of fiberglass. And an additional layer if you think kids will be goofing around with it... and a fourth and fifth layer if you want it to last for 50 years.

4. Then use Bondo body filler to smooth it out.. Yes, I am talking about Bondo Body Filler... the stuff dries in 20 minutes and is really a joy to use (even if it is cheap and sorta "junky" by most peoples' standards).

5. Sand, smooth, prime, and paint.

[Redsky]

actually if you want a real cheap bouy..someone will likely give you a 30-55 gallon white plastic drum...only opening are the bungholes in the top....set it on a level surface pour 2" of liquid concrete into botom let it set ..add some cables cinched around it so you ahve a handle on to to grab it with and a anchor loop connection in bottom....the commenly come in white however other colors are avaliable...if you want a new barrell usplastics.com

[momo3]

Do you guys see many homemade buoys? I want to make a buoy that would be more of a decorative sculpture. And I'd like to mass produce it. But the DNR is giving me the runaround on all of this. I am sorry but I can'[t get too detailed of my design, as I want to patent it. But its someting fun, and it would be 200 feet from teh shoreline on lakes. What do you guys think of this? (Sorry this is off topic)

[Redsky]

the Dnr probably dosent want to give a answer due to the fact that dept of ecology probbaly has competeing rules or dept of licensing/boats seeing its minn. try the coast guard offices on the big lake. if anyone has the specs on a bouy they will.

[momo3]

i mean, it would be within 200 feet of the shoreline. Many people have homemade buoys on our lakes - like milk jugs, etc. where they have their rafts tied up. I dont it it, as people can have rafts and trampolines near their docks. But the DNR doesn't like my idea of having a simple design. My sculpture is very simple, not a complicated object.


ANYWAY, anyone have any suggestions for paint?

[Redsky]

see thats the thing...most people havent probbaly asked...and its a "grey" rules area id guess , and you'v asked to make a offical something....its in/on water so that means deprt of ecology has to review it and the dept of ecology dosent have any rules for it yet! so a study! will have to be undertaken to determin enviromental impact of so may bouys n the water and materials used and specifications drawn up...500k later you get a set of rules and specs that you cant not be in violation of somehow..even with Lawyers! reviewing the rules......dont forrget that licensing fee per bouy now too btw....paint thats simple any hull bottom paint ought to suffice.

[Toot]

I agree with Redsky.

Here's what ya do... you make your buoys and put them in your water. Then you start selling your buoys to other people for decorative use in pools or whatever.

If somebody decides to stick it in a lake or somesuch, then that's their problem, not yours. And regardless, if there is a legal problem with your design, you are sure to find out about it from someone... somewhere down the line. And you'll probably find out surprisingly quickly.

Seriously, what are they gonna do? Throw you in jail because somebody decided to put something you made into a lake? Nah.. they'll threaten you with a fine, you'll fight it, plead ignorance and poverty (i.e., I'm not making a million bucks off these, I'm selling them out of my garage), and show them a good faith effort to comply with their demands and then you're done. Problem solved. No breaching of red tape necessary.


Trust me. In this country, the fear of litigation is far greater than the reality of it.

[momo3]

thanks guys
Yes its something fun that would be near the docks of lakehomes. A conversation piece. But also would work as a "temporary buoy" (to replace the milk jugs, etc. that people use). Perhaps it would be instructed that people take it out of the water each night, etc.

Every time I talk to DNR, water patrol, sheriffs, they shoot my idea down. But they never seem to truely know what they are talking about. Every person says something different. It seems that you can have a trampoline or raft, but nothing else other than certified buoys. I thought I oculd make my buoy a bright color and put reflectors on it...

So do you guys think that I should just produce some of these things, sell them / give them away and see how it works?

Sorry this is a bit off topic. I just realize you guys know a lot about the whole water-scene.

[Toot]

Reflectors may be problematic because certain colors may be mistaken for lighting of a boat under certain conditions, but I have no idea what I'm talking about here.

[Deeman]

If you plan on mass producing these you might make a mold and vacuum bag them and be done with it. Little bumps and dimples are only seem by scrutinising eyes up close. Unseen from 5 ft. away. Like custom cars, they look cool driving by, then when you stop to look at some of them they are awful.
Just a thought.

[momo3]

Thanks for the feedback, guys. You are really a nice group of people. What do you mean vacuum bag them? I haven't thought of this.

And does anyone know if any sort of ornamental buoys have been on the water before? This thing would reside about 10 feet from peoples docks, and would add decor to the lakefront.

Anyone have any other suggestions on who to talk to?