300/440/550 550 Refoam time (Which Foam Help)

[Mark Gomez]

Question is being that this is my first foam Job

For my 1994 550sx
Which will be heavily used in the surf after this job:

1) What kind of foam? 4lb too much for strength?

2) How Much to replace mostly all of the foam in the ski(i took almost all of it out)

and

3) will the new foam come together ok with any old existing foam or does it have to be spotless?

Thanks guys this is a big project for me wait till you see the pics...
-Mark

 

[sxi4evr]

wouldnt it be easier to just by a new ski with more power. i got a mint '95 750sxi for $800.

 

[Mark Gomez]

Im Working on that yet I really want to get into learning glass work and I'm getting alot of help from friends for different rebuild parts.
Im having alot of fun doing this and learning im not looking to flat water barrel roll this im out to have some fun In the surf and make an awesome ski for myself.

But i don't want this to turn into the focus of this thread

Thank you
-Mark

 

[captainfncrazy]

Hi mark
I would suggest using a 2 lb. polyurethane foam,the spec's read that you will get 60 lbs of buoyancy per square ft. A 2 gallon kit will almost cover 8 cubic ft. (Also comes in Qt's)This stuff is nasty!! Make sure you got plenty of fresh air when mixing & during the pour. Once you mix the 2 parts,you got about 15-20 seconds (tops) before it begins to kick...so be ready.I have the same model ski you have & the type of foam used is called a "closed cell foam" provided the foam you took out did'nt crumble apart when you removed it,you should be ok to leave the remainder in prior to pour.I dont know how much you removed,but I'd also suggest doing multiple pours so you dont get alot of over flow in/on your hull.Oh, & wait around 10-15 minutes between pours so your hull doesnt swell. Good luck & have fun

 

[captainfncrazy]

Hey mark
Also,dont forget to start with the fill hole/holes at the highest point so it fills from the bottom up.If your gonna use the factory fill points inside the hull,tilt the ski as high as posible on end so you dont end up with any unfilled voids

 

[Mark Gomez]

well as you will see in the pics I know exatily where my holes were and im all over fixing them. It looks like a nightmare but I was experimenting ALOT before i knew what destruction i was doing. Also I did take out ALOT of the foam almost all of it, there is still a bunch under the fire extinguisher capsule that im going to remove for the Kicker footholds i got ahold of from another project gone south.
I shaved off the tops of the footwells because of the retarded SX plastic molding design. Im going to re glass it flat for an easier and cleaner turf job.
And the reason for the gaping hole in my tray is for easier foam removal and i had alot of holes around there too. I was also more interested in learning the inside of my ski and where everything was. I Do plan to Reglass all of that and i saved the big pieces i cut off to fix the first layer so i can lay an extra strength layer above it.
I've never seen Foam poured so being that I have so much foam out of my ski, would it be better to use the factory fill points which are in the bulkhead??

Really Thank you for your help Im learning alot here and I'm really enjoying this project.
Thanks
-Mark

 

[Mark Gomez]

More pics of my footstrap and homemade foothold destruction

 

[captainfncrazy]

Hey mark
Yes,I'd use the factory hole's in the bulk head after you do all your glassing & finish work on the hull. I just went out & looked at mine & the hole's are about an 1 1/4 across with about 4 smaller one's for venting/overflow.As I said before,do this in step's,meaning multiple pour's until you get them hole's filled.when you get to the final pour,use a piece of old glass,cardboard or paper or anything you can get your hands on to cover them hole's while the foam is expanding.The smaller hole's might puke out alittle foam...but nothing like the bigger one's if left uncovered. Hat's off to you for taking on a job like this cause this from what I see isnt an easy job. It's all about your prep work on how well your glass job will turn out & you seem to be doing great so far!

 

[Mark Gomez]

Thanks allot man
I take it that while I'm pouring the foam in while the ski is Vertical It will go around the pump cavity in there and fill one side of the footwell then flow to the next or do i have to do a little shimmy with the pouring process. Im just thinking and making sure i wont create any big foam less gaps. Maybe I'm making that a bigger deal than it is. but I've never done it or seen it done so i wouldn't know.
Im picking up my footholds tomorrow from my glass shop and might cut out the footwells to fit the footholds. Im Doing all this in stages of free weekends that I have between my senior year wrestling season. Which means my weekends are going to become very busy very soon. But im Glad, Its allowing me to take my time and do my research like this before i get into it all the way.
My upcoming project how im going to get into glasswork will be glassing a strip along the bondline inside the foam area while i have it open. I want to make this a great project and get it done right once. Besides if it looks like ass no one will see it:wiggle:

 

[captainfncrazy]

That's correct,getting the ski on end(pump side down) will ensure your pour will be starting from the bottom end filling any open void regardless of what side is used to pour.Even 10-15 minutes between pour's,if you listen you will still hear this foam expanding slowly so don't over due it like I did the first time using this stuff...lol! Wish I lived closer to you so I could give you a hand with this,but I'm sure you will do just fine. I've been building boat's for almost 12 year's as a hobbie & side work,so I'm no stranger to this foam.Invest in some cheap latex gloves as well,that way if you get this glass or foam all over your hand's,you can peel one pair off & keep going.

 

[Mark Gomez]

Alright cool thanks. I work at a local shop during the summer so im well aware from there and all my projects those gloves are a life and time saver. But hey if you ever convince the family to come Visit Disneyland California let me me know im about 15-20 min away from the place lol
Last question for now. How much 2lb foam would you guess i would need I saw the difference between 2 Q vs 2 Gal was like $100. So im curious how much i would need exactly if possible now that you see my progress.
Thanks again for the help I'll keep you posted for questions.
-Mark

 

[captainfncrazy]

Well,from looking at my js I'd have to say 1/2 of a kit (2 gal. (foam & activator) would do your job & you would have some left over.Here in florida I get my supplies from a place called fiberglass coatings www.fgci.com They have a great online catalog so you can get a rough idea on prices. The catalog I have here is last years but you will be looking roughly around $60-$65 for the kit(2 gallons-A/B)If you have anymore question's,please feel free to ask.California is a long way from here,but if I ever make it out your way,I'm leaving my woman here...she drives me nutts!!(lmao!)serrious..she does

 

[Mark Gomez]

Haha alright then sounds good thanks again
I looked at the Catalog, but I think I have to be a member to see it because none of their product comes up.

 

[captainfncrazy]

Not a problem at all.I just went on their site & it has changed since I've last been on there. When I went in,I went right to catalog & it let me in.I was'nt too far off on the price,it was about $37 buck's per gallon(A/B)I'm gonna send you a pm to let you know of a few more thing's that will make this job alittle easier for you

 

[Mark Gomez]

Awesome man I can't thank you enough
Thank you