Floatation Foam: Pour vs Mold Advice

T

TheSt

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C Dory Year
1990
C Dory Model
user_field_choice.c_dory_model_16_Angler
I am trying to determine the best approach to to adding buoyancy foam to my 1990 16' Angler. The factory gunwales are open to the deck (i.e. an upside down U channel rather than enclosed). The boat came with two long trapezoids of old Styrofoam that (sort of) lock into position.

Option one:
Glass the bottom and sides of the gunwales (I enjoy doing glass work). Place 2-3" conduit and pour. Add drain holes? I think I would get ~%20 more volume, which would allow for more cut-outs and storage.

Option two:
Create a mold and pour new foam that conforms to the original trapezoid removal pieces. Keep it simple?

Thanks
 
I have a new to me 16 Angler, which while I was in the process of replacing the depth finder sensor, I discovered some birds had previously nested in a hollow they had excavated from the foam.

I think I will try to create molds, line them with something that the foam will either not stick to, or simply enable me to remove them from the mold.

I am not a big fan of the Styrofoam used in the original construction, as it is easily degraded (little foam balls all over the place.) With recent bans in the state regarding Styrofoam coolers, I'm not sure about the ability to get something suitable for this use-case.

The Total Boat 2 part foam sure is spendy... though probably definitely worth investing in to keep the boat afloat in an emergency situation
 
A closed cell foam is needed for its resistance to absorbing water and mold, I believe you can buy it in blocks as well that could be drilled and a rope or 1/2" pvc pipe run through them and fastened up under the gunwales.

Regards,

Rob
 
You can also use cheap single-use canned foam to lock foam blocks or boards in place and keep them up and out of the way. I use canned foam so often that I bought an applicator gun, which allows me to use a bit and keep it around for the next project.

In my photo album under Modifications - Ground Tackle it shows where I foam glued the original EPS blocks into the bow.
 
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