The “old codger” of my local club has constructed several foam-core boats. He is not online but I thought his project idea should be, so I’ve assembled this page…
http://home.att.net/~galt_57/foam_boat.html
cool
I see you also posted it on http://www.qajaqusa.org/cgi-bin/GreenlandTechniqueForum_config.pl
Questions:
Any idea why the hull was painted before glassing?
There are poly-urethane panels available for variety of home projects. Did he consider using those? They are more expensive, but was the cost the only concern?
What is the weight?
and is the inside glassed?
Syrofoam Boat Building
– Last Updated: Aug-23-07 10:57 AM EST –
Thanks for posting and "The Old Codger" did a nice job.
I built two boats with a similar technique, but used PVC pipe stringers over my temporary stations, covered that with shrinkwrap plastic, then layed my glass over that. Layed up the hull first, popped it off the shrink wrap since the epoxy doesn't bond to it then did the same for the deck. Joined the two togther and seamed it the same way any other composite boat is built.
If I were to do it again I would build a foam hull exactly as he did then cover it in shrink wrap plastic. Glass the whole thing as one monocoque structure. Cut through that where I would put my cockpit and hatches then pull the foam hull out through those openings. This would eliminate having to seam the deck to the hull and it would eliminate a tad bit of concaveness that you might get laying glass over a PVC -shrink wrap plastic skin on frame structure from the origional building technique I used.
http://outdoors.webshots.com/album/172013009rnQUrH?track_pagetag=/page/photo/outdoors/kayaking&track_action=/ViewActions/FullAlbum
http://outdoors.webshots.com/album/172002130MSYwou?track_pagetag=/page/photo/outdoors/kayaking&track_action=/ViewActions/FullAlbum
Slick process!
What was the start-up and 1st run materials cost? How much time was invested? This could be a good alternative for those looking for a hard-shell version of their favorite SOF.
…and just in time for the off-season. 
Jim
Questions
– Last Updated: Aug-24-07 5:03 AM EST –
Q: Any idea why the hull was painted before glassing?
A: I think it was painted after it was glassed.
Q: poly-urethane panels available for variety of home projects. Did he consider using those?
A: I don't know but I think he liked the easy availability of the cheap foam.
Q: What is the weight?
A: I thought it was 30 something but I'll check.
Q: and is the inside glassed?
A: Yes.
Q: material cost?
A: Obviously the epoxy is the major expense, so I'll have to ask how much epoxy was needed.
Q: time invested?
A: I'll have to ask.
Trmoraine: That is a nice speedy looking boat you have created. So how many layers of glass? The 15 footer looks nice too. Webshots doesn't give much room for describing how you did it.