foam kayak

[James1]

I cut a kayak out of a block of foam, this is a 10 foot sit on top kayak, Now how would I go about fiber glassing it? what type of cloth would I use and how many layers would be needed for it to be strong enough? any and all information would be greatly appreciated. thank you

[billy c]

usually there is some support lent to the foam thru a stringer(s) running the length of the hull. i do not think you could get enough strength from just a few layers of cloth.

[vupilot]

Most epoxy's eat foam. You would need a foam safe epoxy.

[James1]

what would you recommend putting inside of it for support? I'm going to use West System epoxy because it will not destroy the foam.
if I cut the foam block what should I put inside it for support. what if I cut it in half put a piece of fiberglass mat on both sides and put it back together? I want this thing to be as light as possible but also strong enough. thank you for your comments keep them coming please. Thank you

[billy c]

...one more post and you can then attach a picture for us.

[James1]

It's expanding rigid urethane foam is a closed cell, pourable foam, which will resist the absorption of water

[James1]

they build kayaks out of hollow plastic with injection molding. I was thinking that fiberglass would be stronger than plastic so cutting a kayak out of foam block and coating it with fiberglass I was thinking should work I was hoping someone could help me out with what type of fiberglass and how many layers would be strong enough.

[jamundsen]

Many years ago when I was a kid we had a 10 or 12 foot sailboat that was entirely made out of foam with a piece of wood across it for the mast step. It had no fiberglass on it. We sailed it for two or three years until a wind storm caught it and broke it in half. Maybe a couple layers of 6 oz cloth with minimum resin would work. Im not sure if it would be any lighter than a wood one.

[billy c]

yep, had one of those sailboats too think it was called a Snark?
was thinking more on the line of my windsurfing surf boards foam composite construction where they are vacuum bagged and makes a very solid light hull.
lots of info out there for building those so Google is your friend

[James1]

Great info guys. Thanks alot for the help and anything else you may have I'd love to hear.

[vupilot]

Yep, we still have one of those Snark foam sailboats. Probably hasn't seen water since I last sailed it 15 years ago.