Keep it simple. Rebuilding a 20 into a no frills fishing/work boat.

[FishStretcher]

Vinylester is epoxy. And the low viscosity stuff you have- Vipel F010 (right??) will likely get in a crack as well as or better than a thick epoxy (like what you get from West System). Everything I can find shows BETTER mechanicals than something like West System- strength and elongation. Different hardener systems, but both epoxies. So I'd be comfortable with what you have, personally.

For the keel- yeah, fix it now. Lots of layers, getting progressively wider. I have some biax and DBM left over if you want to try something different. And I think some kevlar woven roving. That might be interesting on the outer layer. It will take you a week to cut it.

With respect to the white looking glass: Maybe you got bad/ no sizing on the glass, or it got dirty/oily or a silicone on it?

[brasuk]

vinylester is about as far away from epoxy as you are from Mars.

Epoxy is not in anyway in the "ester" family.

[FishStretcher]

Epoxies come in many forms. The aliphatic amine ones that most people here know, I know there are aromatics and more. But the data sheet for the product in question is clear- it is an epoxy. Specifically a DGEBA epoxy with styrene. West system is also a DGEBA epoxy. So is the stuff they line soda cans with. That is the bisphenol-A that people worry about.

I am not a polymer chemist, nor did I sleep at a holiday inn express last night. I had a few college classes on this 20 years ago. But the data sheets seem pretty clear.

[WildBill]

Bisphenol A diglycidyl ether (commonly abbreviated BADGE or DGEBA) is a chemical compound used as constituent of epoxy resins. It is a derivative of bisphenol A that is used in epoxy resins for its cross-linking properties.[1]

Many standard epoxies are based on a formula containing diglycidyl ethers, including BADGE.[2] Epoxy resins are crosslinked using hardeners (curing agents). The most common curing agents for epoxy resins are polyamines, aminoamides and phenolic compounds.[3]

BADGE is listed as an IARC Group 3 carcinogen, meaning it is "not classifiable as to its carcinogenicity to humans".[4] From the 1990s onward, concern has been raised over this possible carcinogenicity because BADGE is also used in epoxy resins in the lining of some tin cans for foodstuffs, and unreacted BADGE may end up in the contents of those cans.[1]

DARN; you can't even drink a Diet Coke

[Basketcase]

The kevlar is an interesting idea! I think this project is going to wait until spring. I don't have a heated work space so weather is crucial. With the cold weather I just dont want to roll the dice. I also don't have enough resin to complete the job in one lamination so I think it's best to wait until spring and I'll get another pail and go at it. I may do some templates for the deck over the next few weeks, and maybe start on the mold for the transom boxes/cap but I think fabrication is done for the year.

[Basketcase]

So its getting to be time to order a fuel tank for this boat. Looks like I have a few options. Poly, aluminum, or stainless. Which one would be best suited for an under deck application? I do not plan to have an access hatch. Im planning on installing it and putting the deck on top with an access for the fill/sender etc. I know if I ever need to replace it that I have to cut the deck up but I'm not afraid of that. Any thoughts?

[FishStretcher]

Plastic can't corrode. Metal can. You can look at my tank if you are interested- it isn't in yet.

[FishStretcher]

One more thing with plastic. You are supposed to put a foam pad (neoprene?) between it and the structure surrounding it. Ostensibly for expansion, but I expect for surface irregularities, too. I plan on foam wrapping mine and 2 part urethane foaming in place. Haven't done it yet.

[Basketcase]

That makes a lot of sense. I really like the idea of foaming in a tank because we all know how well that stuff sticks to EVERYTHING (except most plastics) and i feel with a good cradle and some foam poured around it that the tank is quite secure. Since foaming in an aluminum tank leads to its early demise then a plastic tank just seems logical.

[Basketcase]

It's been a while so I figured Id post some updates. I did go with a plastic tank and did NOT foam it in, per Moeller's instructions. They said that foaming it in would not allow for expansion and would void the warranty. This tank had 8 screw bosses in the top that I used to secure the tank with in addition to some stainless straps that I had made by a friend. I left a .5" gap all around and used neoprene foam in between the straps and tank and also a .5" pad underneath it. It's quite secure.

I'm a little farther along than I have pictures of. When I put it to bed for winter I had glassed in all of the deck. I used 2 layers of some 24oz cloth I got for cheap. It looks just like 1708 but MUCH thicker. All vinyl ester resin. The underside of the deck has one layer of this cloth on it.

To secure the deck to the stringers I used a billion tubes of 5200 and stainless deck screws. Once the deck was secure I hole sawed some small holes and poured foam into the two outer stringer bays and portions of the inner ones. The outer bays will be SEALED with no protrusions (screws, etc) so there should be no chance of water intrusion to the foam. In the inner bays, since water intrusion is possible, I covered a piece of 3/4" pex tube in mold release before I poured in the foam and pulled it out after to leave a channel at the lowest point so hopefully gravity will help me out if water does seep in.

By pouring the foam in after the deck is in, it is able to completely fill the cavity and also gives extra adhesion of the whole assembly. Anyone who has tried to pull foamed parts apart will understand. I did this on my other boat and it worked great. You just have to be sure not to do too much at once or there is a real risk of popping the deck from the pressure.

Once the foam was in I then did my two layers of glass over the entire thing, sealing the foam holes and all the screws. I feel bad for whoever tries to get this deck off some day.

On to the pictures!