Re-attaching the foam

cprettyman

New Member
So, I have a very old (pre-72 I think) sunfish that, after some time spent with fiberglass and gel coat, is watertight again for the first time in years, and I took it out this weekend and had a great sail. On to the next big challenge:
The foam blocks inside are clearly detached from the hull, so I am going to need to get in there with some adhesive. Can anyone recommend:
- Type of adhesive
- how to get in there (would one inspection port somewhere do the trick, or do I need port and starboard access? I already have access ports near the bow handle and the stern from otehr repairs, and would like to keep the number of holes I cut in the boat to a minimum.)
- a process to get the adhesive in there well?
- any and all advice welcome

Thanks!
 
I made a similar repair in one of my sunfish. The block on the port side of the bow was loose. I cut a 5" inspection port between the splash rail and daggerboard trunk (a 6" port would have made it eaiser). To rescure the block I first ripped out as much of the old evpanding foam as i could and then filled the gap between the block and hull with great stuff brand expanding foam from a hardwhare store. When I first made the repair I had doubts as to how long the cheap hardwhare store foam would hold up but the boat has a summer and a half of use on it since the repair and the hull is still nice and stiff where the repair was made and the block is secure.
 
I am glad the repair is holding up for Alcort59224, but there are several contributors to this Forum who have advised against the use of Great Stuff for reattaching foam blocks.

Typically, a two-part foam is recommended, for instance see:
http://www.sunfishforum.com/showthread.php?t=28882

Of course, whether a repair will hold up or not will depend to a great extent on the conditions the boat will encounter.
 
Thanks
There is a fan blowing air from my inspection port at the stern through the hull and out hte inspection port at the bow now, to dry out whatever water got in there during the weekend sailing. Thursday night, I'll pop in the center inspection port, and then start he foam repair. I already had plans for this weekend which will keep me off the water (sadly, since the weather reports are great), so I should have a couple evenings to be sawing old foam out and getting ready to pour new foam in.

THe windline site is great, because it made me realize that I was missing something astoundingly obvious - I always pictured doing this with the boat on saw horses, upright. But, for this process, having the boat on it's side makes HUGE sense. Duh me!

Thanks!!!!
 

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