Well, it’s been a while since I’ve updated my thread. I’m a year into it and still making progress. I can now confirm that the conventional wisdom here is correct. Estimate how long you think it will take and how much it will cost and double it. That being said, I have no regrets. I just want to be done and get this thing in the water.
I’ve done a lot of fairing and priming on the top cap and in the cockpit, but it’s still not done, so I’m not ready to post pics. It’s been so hot lately, I decided to do some stuff that could be done inside the shop. Man, am I glad I put in that A/C unit.
I originally planned to use blue Styrofoam to insulate the fish box, but after considerable pondering, I came to the conclusion that it would be way too much work for a questionable result. I decided instead to laminate the tub into the outer box and then fill the void with 2lb. density polyurethane foam. It seems to have been a good decision. Here’s the process I used:
First, I used thickened epoxy resin to glue the tub into the outer box.
After I flipped the whole thing over, I tabbed the two parts together, used a piece of scrap masonite to build a form on the open end of the box, and poured two part foam around the tub.
Before foaming the bottom of the tub, I put in a drain.
I wasn’t sure how much leakage I might get, so I covered the bottom of the box with visqueen before I put a rigid form over it.
Then I clamped and screwed a piece of sign board over the bottom to create the form.
Here’s the gap to be filled.
And after the foam is placed.
And with the form removed.
The insulation really stiffens up the structure. The tub is solid as a rock. In hindsight, I probably could have gone lighter on the laminate for the outer box, but it is what it is.
I’ve done some other stuff that I’ll try to post in the next couple days until I’m up to date.
Dave