Wet Foam Aftermarket Hull

[Balduccimoto]

Cut it open and get the wet stuff outa there, replace with poly or sheet foam and then install 2 small drains in rear of hull.. Its not as bad to do as it seems.

Good. I'll drop it off tomorrow morning lol.

I looked where the intake grate bolt was removed. It's still leaking (slowly) since early October and lots of salt on the floor left from evaporated salt water. My concern is, OK I cut the tray and remove the 2 part foam then I replace the foam with home depot foam. Inevitably there will be air voids. Wouldn't this compromise structural integrity of the tray and need gunwhale reinforcement? This is surf ridden and hopefully soon learning barrel rolls..

 

[yamanube]

Yes it definitely could, however there are a couple other factors. Being that this is a Waterdawg hull (assuming based on your signature) there is likely already air voids and pockets of improperly mixed foam, the more time cutting and shaping the extruded poly you spend, the stronger the assembly will be.
Some guys add two part foam to the poly to fill the voids that are left over, this foam will soak water but is a considerably smaller amount than it is now and should make little difference in weight even after its soaked.

 

[MADMAT]

I have tons of air voids via ping pong balls and my ski can take horrible landings and throw aways from 20 feet up. ...you just have to be MOSTLY supported and make the glass or carbon extra heavy duty IMO. And yes I felt a immediate difference after ditching wet foam on my AM hull.

 

[Balduccimoto]

Okay, in the pic I took up some turf at the rear of the tray because it delaminated at the bondline from the trim hitting the end of the weave. Where should I make a cut? When it is replaced, do I just put a sheet of carbon where the edges meet like footholds?

EDIT: Forgot to add the picture lol

 

[madness maker]

here is a pic of my old octane when i cut it open to refoam it, i would do something similar on yours..

 

[Balduccimoto]

Yeah I was thinking of something like that and just cut around the footholds. They are actually huge and extend far towards the front of the tray

 

[MADMAT]

http://www.x-h2o.com/index.php?threads/another-refoam-thread.113110/

 

[Balduccimoto]

Thanks for the link madmat. Okay so I have a plan and a helper. My plan just about ends with putting the tray back on. I am going to use a thin cut off wheel to get a clean cut. That way when it goes back on there will be minimal gap. I'll fill the gap with thickened resin then use a few layers of 3" carbon tape on top. Is that sturdy enough if the tray has enough foam support?

 

[Joker]

If you wqnt to reuse the tray part you cut out I would do three layers or 1208 biax 6 inches wide. And it will be damn near unbreakable.

 

[yamanube]

3 layers of 1208 is a lot.

 

[Joker]

3 layers of 1208 is a lot.

I would rather have 2 extra lbs on my ski and it be unbreakable than worry about it breaking. I layed my tom21 tray in my fx1 with 3 layers of 1208 all around and 4 on the dash area. That thing is stronger than an ox and could handle rosey odonnel standin in the tray

 

[Scraggly]

I don't have that much in my tray and there is no foam also. Very strong and still light. Mine is a mix of carbon, 18oz twill mat, and a little e glass around the holds under the mat.

 

[Balduccimoto]

Well all the foam is out. I weighed all the foam and it was about 6lbs. There really wasnt that much water in there. I wish I hadn't did this What a waste

 

[Joker]

Damn dude thats a bummer

 

[Balduccimoto]

Damn dude thats a bummer

Most of the water was in the front from when I rode with no intake grate. It was just a waste of my labor is all. Either way I had to buy the materials to fix a few layers of carbon that came up on the rear bondline.

 

[tomski]

Well all the foam is out. I weighed all the foam and it was about 6lbs. There really wasnt that much water in there. I wish I hadn't did this What a waste

You were just doing it for practice.

 

[yamanube]

Look at it this way, if it was leaking, eventually it would have soaked all the foam and eventually would have turned into a heavy mess. Just preventative maintenance, and dry foam is less of a mess to remove than wet foam, win win.
How did it look as far as mixture and expansion? Any voids or pockets of improperly cured foam?

 

[Balduccimoto]

There was a small void to the foward right of the tray.

 

[TontoM3]

at least you can reinforce the tray. fix the delamination, install some drain plugs and add a preferable foam. plus if you fix the tray with what you mentioned it will be indestructible. and you have time since there are a good three months between now and riding season.

 

[MADMAT]

People pay big bucks around here to shed 6lbs! Plus it was probably more like 8 or 9+++lbs before you let it sit and drain all that time....and it was only going to get worse IMO.