Reconditioning the internal floats

JBAPAG

New Member
I have a 1973 sunfish, in the 80s there were kits that one could buy that would allow the owner to insert portholes in the bow and the stern of the deck, allowing for replacement and drying of the internal styrofoam. Does anyone know if the kits are still available or if there is a better way to recondition the internal floats? JBA
 
I don't know if you would call them kits, but it is pretty standard for people to put portholes sunfish. I would say that most boats have portholes. You can buy them online from companies like Beckson or at a marine supplier like West Marine. If you search this forum you will find a lot of information about how to install portholes, where to put them, what size to use and how to dry out your boat. These topics have been discussed in depth in previous threads.
 
I guess that those kits are from a bygone era. But there are numerous threads on installing ports to dry the (six) internal foam supports, and the repair page that Wayne noted is excellent. You can use the Search function (upper bar) to find other references.

Replacing a foam support block is a major headache and hopefully, won't be necessary.
 
greatstuff3.jpg
 
It looks like ordering this foam directly from the MFR is much better than any price I can get locally.

Which density is recommended?

How far does the 4 LB kit (the smallest one) get - what I mean is, if every one of the foam blocks were 100% detached top and bottom, so I need 100% re-attachment, would 4 pounds do it? By that measure, my own project needs somewhere closer to 10% - 25% re-attachment, and I am trying to gauge how much foam I need.
 
When you cut your ports, be aware that at least on the early '70's models, that whole back deck appears to be encapsulated in a about a inch and a half of solid teak. Everything back there - rudder system, bridle - was screwed right into the teak. These things were very well made....
 

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Which density is recommended?
4 lb density (4 lbs polyurethane per cubic foot)

How far does the 4 LB kit (the smallest one) get.
The small kit will probably leave you with a little left over, but it's a good idea to do a small practice pour.
http://www.windline.net/project3.htm

U.S. Composite FAQ
8. How much do I need to order?
You will need to calculate the volume of your cavity by multiplying the length x width x height
Example: 2 Ft x 2 Ft x 4 Ft = 16 CUBIC FEET

If calculating in inches convert all measurements to inches
Example 24 inches x 24 inches x 48 inches = 27,648 CUBIC INCHES. Now to convert to cubic feet you much divide that number by 1,728 which equals 16 CUBIC FEET.




When you cut your ports, be aware that at least on the early '70's models, that whole back deck appears to be encapsulated in a about a inch and a half of solid teak. Everything back there - rudder system, bridle - was screwed right into the teak. These things were very well made....
The new boats have better control on the pour-foam overage.

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Your earlier build has a lot more overflow... not that it matters.
 

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What you are look at is foam and expanding foam overflow. Lots of overflow. The wood backing strips were thin pieces of wood with a fiberglass strip of cloth covering them. If you have the wood screws and not the machine screws you have the wooden backing blocks. You'll have to cut away some of the center block but there will be plenty left.
 
It looks like ordering this foam directly from the MFR is much better than any price I can get locally.

Which density is recommended?

How far does the 4 LB kit (the smallest one) get - what I mean is, if every one of the foam blocks were 100% detached top and bottom, so I need 100% re-attachment, would 4 pounds do it? By that measure, my own project needs somewhere closer to 10% - 25% re-attachment, and I am trying to gauge how much foam I need.


Okay so I did reattach the two side blocks in the front of the boat. and bought the 4lb 1/2gallon kit (part A and B two quarts.) I used 4/5ths of the kit to reattach the blocks because the blocks didn't have any foam holding them. so it was like starting from new. My boat must have been a friday afternoon boat. lol. But now its awesome! its like brand new and very stiff!
 

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