Freestyle Fixed! my leaky Gen3 b.o.b PT2

[Quinc]

Maybe, except I finally got a reply back on facebook from them. "Back on the Gen3 days, we used foam to fill the voids under the engine mount plates. Not sure why foam would be anywhere else, other than under the engine mount plates"

 

[Quinc]

Is it foam like this: http://www.fibreglast.com/product/Vinyl_Foam_4lb_Density/Foam

If so, it could be a foam core, sandwiched within the composite. There's almost no way that the gelcoat is the only remaining layer, gelcoat is similar to paint, it's just a surface layer that is extremely thin and doesn't offer any kind of structural support.

That's it! the foam is between the resin and the hand laid carbon inside the hull. Should I get more of this foam, epoxy it in the same place and put a couple layers of sglass over it? Or just use sglass?

 

[Nate_D]

Just glass it in my opinion. I'm no expert, but that original layup looks highly questionable. The foam they used looks more like a polyurethane pour foam than a vinyl core sheet. Could be wrong though.


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[hink320]

I agree with Nate on just glassing it. The only way I might recommend going with a core material is if you're going to vacuum bag, otherwise I'm sure you'd end up with some serious voids in your layup.

 

[Quinc]

Some real good news for once! The exhaust side of the ski was not nearly as bad as the scupper side. So I didn't need to sand nearly as much off. Couple little spots in the tray I need to get to by hand and she should be ready for glass.

Next up is the firewall.. It was sealed or was attempted to be sealed with rtv and 5200. So sanding that out has been a bigger pain then you would think.

For the really good news. Other then 1 bad spot in the engine bay it looks pretty solid, I sanded though the carbon in a couple places on the bond line and it has already been filled with epoxy. So going to go clean up a few spots then it will also be ready for glass.

Now I need to order everything...

 

[Quinc]

Now that Pismo has come and gone I can get back to embracing the itch. After a little more sanding on the spots that where dripping water I figure I might as well patch them and lay a layer of glass on the bottom of the hull.

After an hour of sanding with 60grit she looks good as new with a little simple green.

 

[Chris Pausch]

Sub'd. This will give me ideas if my bob ever decides to take in any sort of water. Wonder if there's a difference in build between the carbon and glass lay up

I was wondering the same thing, I'm working on a glass gen 2 and this thread has got me freaking out a little

 

[Quinc]

4" sanding disks = awesome. Turn down the air a bit and the disk flex and form to the hull and get a lot of the nooks and crannies. I think *hope* I got the engine bay complete and just need to finish sanding off the paint, then she will finally be ready for glass!

And pulled off another one of these gems..

 

[Quinc]

Finally done sanding! For now anyway... To say something good about the ski clinic they use a crap ton of paint and primer. Just taking off the small area around the tray I will be laying glass took a while with the 5" flapper wheel.

Removed the foam and carbon around the hole to help with maximum bonding.

After I was all done I hosed her down and put her in the sun to dry:

Didn't bother taking a photo this time, but in true ski clinic fashion I peeled off a chuck of carbon and the gas tank mount came off with it... Here is hoping they did a better job with the engine mounts...

 

[Nate_D]

Finally done sanding! For now anyway... To say something good about the ski clinic they use a crap ton of paint and primer. Just taking off the small area around the tray I will be laying glass took a while with the 5" flapper wheel.

Removed the foam and carbon around the hole to help with maximum bonding.

After I was all done I hosed her down and put her in the sun to dry:

Didn't bother taking a photo this time, but in true ski clinic fashion I peeled off a chuck of carbon and the gas tank mount came off with it... Here is hoping they did a better job with the engine mounts...

This sort of stuff really frustrates me to see. I'm glad you are through the worst parts of it though. I would go ahead and rip out those motor mounts and redo them just for peace of mind. Bulkhead is already set, so lining up the replacement mounts is easy.

Keep up the good work bro.


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[Quinc]

Filling in the bondline! Almost but not quite a peanut butter consistancy. Hoping it will settle down as low as possible. I will put another layer if needed. Then it will be covered with glass.
The yellowish brown is the failed attempt of gluing..

 

[Quinc]

Splooged the other side last night. Need to hit up walmart after work and get a food scale for weighing the glass/resin.

 

[Quinc]

Finished the firewall! Now do I do the engine bay sides then bottom, or bottom then sides?

Much easier to work on a flat surface by hanging the ski from the ceiling by the nose.

 

[yamanube]

I'd to bottom then sides so the overlap ends up on the bottom and pretty much hidden from view.

 

[Quinc]

EDIT: The Helicoils where installed by the PO and not by the ski clinic.

Keeps getting better. Nothing like heli-coils for pump inserts..

 

[Sanoman]

Keeps getting better. Nothing like heli-coils for pump inserts..
View attachment 307193

Wow! OK,l get the slogan "backflip on a budget" but this is way beyond

 

[Quinc]

After seeing the quality craftsmanship of the bob, figure better safe then sorry so using the 12oz for reinforcement of the engine mounts.

 

[billman100]

I thought I was suppose to be on a budget, not the craftsman


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[Chris Pausch]

Are you using something to dye your resin?

 

[Quinc]

Are you using something to dye your resin?

Resin dye from us composites. Less than 10$, holds up better then paint, and nothing to sand off if you need to make new repairs.