Styrofoam

[werwer6969]

I'm interested in building a boat out of rigid styrofoam and covering it in fiberglass. I was wondering if anyone can tell me if this would work or will the fiberglass eat away at the styrofoam, any help anyone can give me would be greatly appreciated.

Greg

[SamSam]

Fiberglass won't bother it but polyester resin will melt it. Epoxy resin will work. Sam

[frosh]

Greg, there have been a number of threads in the past about the compatibility of resins and styrofoam. Ditto about the structural qualities of styrofoam and other core materials Ditto again about the water penetration issues of the various foam materials.
Suggest you research them yourself, and you will answer your own question.

[Ike]

plus all that, and penetration by gasoline, other petroleum product, and alot of cleaners, will dissolve styrofoam. You would be better off using polyurethane foams, They are resistant to gas, oils and solvent, as well as resins.

[JR-Shine]

Polyurethane foam makes for a very poor hull core also, mainly due to its peel and shear strength (or lack thereof). Low density PU can be used for insulation and flotation or as a “form” over which you laminate fiberglass. This is not the same a core it does too participate in the structure - it just takes up space. Higher density PU foam is OK for areas of high compression like a transom.

PVC foam (Divinycell and the like) are what you need for a hull core, or Corecell. I know the DIAB site (maker of divinycell) has a page on how to build a boat by strip planking a jib with foam, then glassing

Their site is www.diabgroup.com

Good Luck,

Joel

[werwer6969]

Thanks to everyone for there input. I was interested in building a kayak or canoe out of styrofoam, then covering it with fiberglass. maybe I should just consider doing one out of door skin and covering it with fiberglass.

Greg

[rgranger]

Greg

All the things these guys said is basically true but I feel you were asking a different question than the one they answered for you.

Look at this site.

http://homepages.paradise.net.nz/garyd/quikama.html

This is a commercial boat builder using styrofoam core.


You can use closed cell styrofoam covered in epoxy based fiberglass with no problems. It is rigid and resists water penetration. If the foam is completely covered then there is not an issue with solvent degradation. The blue foam pictured in the above link is nice but DuPont makes a 3" pink version of the same stuff. Home Depot caries it in 3'x8' sheets. A kayak would make a nice project and two layers of epoxy glass and you would have a light an strong boat.

One more thing. PU foam will handle polyester resins but it does not like epoxy. PU foam core is what surf boards are made out of. If you want to go PU look up some sites for surf board foam.

Some people like polyester and others like epoxy.

C-ya on the water.

rob

Sure you did notice that this thread died already three years ago!?

And for a good reason: Styrofoam has nothing, absolutely nothing to do with boatbuilding! There is not a single application one could use that stuff.
And what you call a "commercial builder" is just a backyard tinkerer.

Regards
Richard

[gonzo]

Styrofoam works well as insulation. We have also used it extensively on hard tops and decks as a core between thin plywood. We used epoxy as an adhesive. The close cell polyurethane is rated for ground contact.

Originally Posted by gonzo

Styrofoam works well as insulation. We have also used it extensively on hard tops and decks as a core between thin plywood. We used epoxy as an adhesive. The close cell polyurethane is rated for ground contact.

Poor choice Gonzo! I regret to say that, there is better stuff around at almost the same price.

[gonzo]

Name one better material at the same price. Also, please explain why it is a poor choice. Have you done any testing? Commercial boats have been working for years with decks and hardtops built like that. It seems like your opinion is not based in facts but preferences.

Almost the same price I said! We are talking insulation and we are talking sqare meters not acres right? Then the close cell Cyclopentan expanded PU is the far superior choice. You are too professional that I must declare why!
And of course it´s my opinion, based on technical properties not preferences. Professionals do´nt have preferences, they strictly use the best material available for the job, or they are not long amongst the professionals.
But as a structural member (and that was the original question) even that PU foam is not the best choice, let alone the white crap.

Regards
Richard

[gonzo]

It pink or blue not white. I am talking about the closed cell foam. In spite of your rather emotional posts, you are not naming any material at about the same cost as the close cell polyurethane that is better.

[Steve W]

There are applications where styrofoam will do the job ok,an example where i have used it was on a 24ft ULDB which i designed and built in 1987,the hull used klegecell and vinylester,the decks were ply/klegcell/glass but as i was installing full foam floatation under the berth tops i made them of 1 inch pink foam with a layer of glass cloth /epoxy on each side,peppered them with 2inch holes and glued them down and poured 2 part bouyancy foam thru the holed and let it foam out the holes like cupcakes and then cut them off and put light glass over,a lot lighter top than plywood or any other foam for that matter and laughably cheaper,has worked great for 20 yrs.I have also used it as a core in a doghouse top glued with resorcinal which i think works better than epoxy for this application(for many other too)but i also included WRC 1x around the perimeter and as beams across so it was 4mm ply as the bottom skin,wrc perimeter and as beams on maybe 16in centers,styrofoam glued between and 4mm ply top skin dynel sheathed,worked well.
Russ Bowler built the 18footer "Benson and Hedges" in my shop 30 something years ago out of polystyrene/epoxy with an aluminum space frame to take the huge rig and daggerboard loads. CSK built a small bridgedeck cat back in the 1960s appropriatly named Foamy which was raced in west coast races down to mexico. Malcolm Tennant regularly speced ply/foam/ply with polystyrene for bridgedecks.I personally wouldnt use it for hulls as it has very low peel and sheer strength, but as with everything it does have its uses.
Steve.

[boat fan]

It would not really make much sense using it for a canoe. or kayak.

Much easier to use single skin plywood and you can always add floatation with water tight compartments or foam.