Did this once.

Glassed the plywood into place. Drilled the holes like you described, 1
inch dia. The spacing used is about the volume of foam in the expanded
state. I had the boat on a trailer, tilted it as far back as I can. Idea
is to get the foam to flow towards the low point away from the pour hole and
as it expands it fills the cavity up to the hole, then proceed to the next
hole and repeat.

Now the fun part, I used 1 litre juice or milk cartons. Collect many. Mark
or visually identify the half and quarter positions and use those to measure
the 2 part stuff. Work fast, stir as quickly to mix and pour it through the
hole. We are talking seconds here. Pour it like you would with a kettle,
it can be done. You have to work fast. As you mix the half litre mix, it
will come to the brim very quickly. Pour quickly, if you pour too slowly it
will overflow.

Have a large garbage bag handy and opened and ready to receive stuff on
short notice. If things get out of control dump everything into it.
Spillages are not easy to get off.

After you've poured the stuff in, put a plastic sheet (plastic bags are ok)
over the hole, cover with a flat plywood and put a brick over it. You can
feel the heat from the reaction and it'll tell you where its reached. Be
careful in confined spaces, it can build enough pressure to burst seams.
When everything is done, glass over the hole, you don't want water getting
in.

Added precaution, the stuff releases toxic fumes. Work in a well ventilated
place, run a fan.. Don't work with your head in a confined corner. Have
another person around as a precaution.

Good luck and be careful.


"Ed Kracl" wrote in message
news:UL2Hc.40867$MB3.13685@attbi_s04...
I have a 1981 SeaRay SRV210 Cuddy, which I've started recondition the
interior on. Upon pulling up the old carpet, I found the floor on the port
side soft and spongy. This boat has a fuel tank mounted in center of the
hull under the floor that runs from the step-down into the cuddy back to
the
engine compartment. There is a foam filled cavity on each side of the fuel
tank which is covered with plywood and glassed in place.

Only one of the cavities showed any signs of delamination of the floor. I
now have the glass and plywood tore off the one cavity from the cuddy
area
back to the transom. Before removing the glass and plywood, I noticed a
pattern of holes (approx. 3/4 inch) drilled through the glass and plywood,
the foam was level with the top of the glass. I have to assume that when
foam was put in, it was poured or injected through these holes and as the
foam expanded the excess foam was able to exit these holes.

Now, I have the water saturated foam dug out of the cavity and letting
every
thing dry out before sealing it back up.

I would like to put the new plywood floor in place glass it in solid,
then
drill the same pattern of holes, and pour in new foam. It seems to me that
the foam up expand up to the bottom of the floor and provide a solid
floor.

A local vendor who sells the foam suggested leaving the top off the
cavity,
filling it with the foam, cut the excess off, and then install the top. I
just don't think I would get a solid floor doing it this way.

Sorry for the long post, but I've never worked with 2 part foam before and
I'm curious if someone out there can share any experiences with me.

Thanks in advance