Fiberglass Question

[Talltails]

I'm building a new console for my skiff. I formed it using Dow insulation board and I am figuring the resin will melt the board. Any ideas on what to line my form with? I thought about using aluminum foil or 4 mil poly. Anyone done this before?

[Chalk]

Sorry to break the bad news to you - but the fiberglass and resin will form around the foam. The bad news is it will not bond to the foam. If you completely fiberglass the thing inside and out, it will be okay, but the strength will only come from the fiberglass. I used the same foam for my fish box and laminated plywood to the foam - there was basically no bond between the wood and foam. Look at Last-A-Foam if you want a cheap structural foam.

The resin will not melt it...epoxy won't melt...I don't think polyester or vinylester will either.

[Talltails]

Thanks, Chalk. I was planning to use two layers of stitch mat and ditch the foam after it set up. I was just worried about the fiberglass resin having an adverse reaction with the styrofoam.

[Chalk]

I know epoxy won't - if your using polyester just put a little bit on a test piece and try it...you will know pretty quick.

[FUTCHCAIRO]

THE LAST CONSOL I MADE WITH FOAM, I FIBERGLASSED BOTH SIDES WITH GLASS AND MAT, AFTER I LET IT SET FOR 2 DAYS, I TOOK MY PENCIL BLOWER POINT WHICH IS 24 " LONG AND BLEW OUT THE FOAM WITH 150 # AIR PRESSURE. I THEN PUT A PIECE OF MAT DOWN INTO THE VOID AND TRIMMED IT FLUSH. MIXED UP A GALLON OF RESIN AND POURED IT DOWN AROUND THE MAT AND THE TWO SIDES. THIS ADDED ABOUT 15 # OF WEIGHT BUT IT IS SOLID MAT AND FIBERGLASS AND WAS TOUGH AS NAILS. WHEN I FINISHED IT I STOOD ON TOP OF IT AND IT DID NOT MOVE AT ALL, AT THE TIME I WAS 237 #. IT IS BEING USED ON A CRAB BOAT NOW AND FOR THE LAST 15 YRS.
PA THE OLD MAN OF THE SEA