Foam / Plywood Boat Plug Construction ?s

[cla17]

Hello,

Background:
I am trying to build my dream 21'6" ski/wakeboard boat. I want to build a plug for an actual production style mold(I trying to build this into a business). I have some auto body and boat maintenance repair knowledge. I have had little experience with fiberglass and none with gelcoating.

Situation:
I have a design I want to build but and am on a budget(who isn't) and want to build a 2 part Poly foam and plywood plug. The plywood for support and the foam exterior shaped to the desired shell. I plan to use a Versi-Foam system to spray the foam, unless you someone knows of a better foam for shaping, but I don't know what tools I'm going to need to shape this stuff and how I am going to coat this foam to be able to lay-up a mold on it?

Questions:
- Is this the right foam(Versi-Foam) to use for this large project?

- What tools am I going to need to shape this foam?

- And what do I need to coat this foam in, to be able to lay-up a mold on it?

Gratitude:
Any advice is GREATLY appreciated and will garnish good karma, my eternal thanks, and a free ride on the finished product whenever you are in Sunny San Diego.

Thanks,

Chris Anthony

Design pics:

[yipster]

hello cla17
only a question back here on a not asked subject. why do ski boats always use a shaft or v drive? why not a sterndrive, to much wake? for more Versi-Foam system info i'm on the mail list now also.
yipster

[cla17]

Howdy Yipster,
Outdrive boats are notoriously bad at holding speed and because the prop is low and very far behind the boat bow rise is a problem. Because of this the hull needs to be more of a V shape. Ski boats want to stay high on the water(a plaining hull) so the V hull is a bad choice, also skiers need a very constant speed. Wakeboarders fair better with a V hull but hate the unpridictable speed and the wake a V hull throws is also a little odd. All in all, direct or V-drives just prove to make better ski/wake boats. Predictable speed, constant wake/no wake for skiers, and more direct power to prop. Hope that answers your questions.