foam kayak

Discussion in 'Boat Design' started by JamesMardis, Dec 11, 2014.

  1. JamesMardis
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    JamesMardis Junior Member

    I cut a kayak out of a block of foam, this is a 10 foot sit on top kayak. How would I go about fiberglassing it? what type of cloth would I use and how many layers would be needed for it to be strong enough? any and all information would be greatly appreciated. thank you
     
  2. Mr Efficiency
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    Mr Efficiency Senior Member

    You best mention what the type of foam is. If it is polystyrene, you have limited options.
     
  3. outdoorplay
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    outdoorplay Junior Member

    you do have options but like he said need to know what kind of foam
     
  4. JamesMardis
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    JamesMardis Junior Member

    expanding rigid urethane foam is a closed cell, pourable foam, which will resist the absorption of wate
     
  5. JamesMardis
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    JamesMardis Junior Member

    Product Information:
    Free Rise Density: 2.0 lbs per cubic ft.
    Expansion Rate: Approx. 25-30x Liquid Volume
    Buoyancy (flotation): 60 LBs per Cubic Ft.

    *Physical Properties:
    Parallel Compressive Strength: 40 psi
    Tensile Strength: 30 psi
    Shear Strength: 30 psi
    Flexural Strength: 50 psi
     
  6. JamesMardis
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    JamesMardis Junior Member

    Thank you guys for the help and any more information you can give me will be greatly appreciated.
     
  7. rowerwet
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    rowerwet Junior Member

  8. JamesMardis
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    JamesMardis Junior Member

    Come on guys help a brother out.
     
  9. garylepak
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    garylepak New Member

    I've built several foam and glass boats and paddleboards using pink or blue styrofoam and epoxy. I always have some wood structure incorporated such as the vertical ply stringer used in surfboard construction, or a 3mm ply bottom, rails along the gun'l, etc. for strength. It helps give rigidity to the structure. Otherwise you will need more glass. I used to use one layer of 6 oz glass but lately have used 4 oz. It gives a smooth finish, adds enough strength, and helps some with ding resistance. With a solid foam boat you don't need to worry about flooding the hull, and dings are easy to fix with a dab of putty. I have even left some deck and cockpit areas as bare foam and have been surprised at how well it wears. I am not especially careful with it either.

    One I am working on now is 11'6" x 22" x 5" thick. It is well under 20 lbs. Right now it is 14.5 lbs and probably around 17 when finished. My 6 year old 16'x20" solid kayak with surfski style cockpit, built heavier, is 35 lbs with 6 oz glass.

    I recently built two paddleboats using thin styrofoam boards as a skin and then pouring two part foam into them. Both have self destructed in a matter of months from the foam shrinking and deforming the hulls. I won't do that again.
     
  10. JamesMardis
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    JamesMardis Junior Member

    Thanks Garylepak,
    I like to hear more about the paddleboards and solid kayak with surfski style cockpit. or any photos you may have. very helpful input.
     
  11. JamesMardis
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    JamesMardis Junior Member

  12. Mr Efficiency
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    Mr Efficiency Senior Member

    Use isothalic polyester or vinyl ester resin, chopped strand mat is easiest to laminate with.
     
  13. garylepak
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    garylepak New Member

    I have a lot of pics of my boats including construction sequences but they are not online right now. If you email me I can send a few. I'm working on a website but always seem too busy building or paddling to put any time into it. I'll try to get some pics up in the next few days.
     
  14. JamesMardis
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    JamesMardis Junior Member


  15. JamesMardis
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    JamesMardis Junior Member

    Thanks for the email Garylepak, Kool photos.
     
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