Foam Expanded, not too sure how too fix?

[ragu78]

I have a 1987 15ft Bayliner Trophy and I am a first time boat owner and don't really have much experience with this stuff. So any help anyone can give or any suggestion would be greatly appreciated.

It seems as though the expandable foam that was poured from the factory has over expanded on the left front of my boat, circled in the picture below. It has expanded so much that it actually crack the plywood that is under a very thin coat of resin, and caused it to bow up-wards. I removed the original cap that was on the fill hole and the foam is dry as a bone, so I'm not sure as to why or how this happened? I am the second owner of the boat so I can't say for sure if it was originally like this, its really was not too noticeable until I removed the carpet for a new carpet install.

Here below is another picture viewing from under the dash ...

Here below is a closer view of the original pour hole and the crack ...

I was wondering how hard exactly of a fix this would be for someone like me with barely any experience in boats? I measured the plywood and it's not even 1/2'' thick plywood. So would just cutting out the piece of plywood, leveling out the foam and replacing the damaged plywood with another piece mess with the strength of the boat? If not, will I have to resin back over the wood (hoping not, seeing as I have never done that lol)?

Or, could I possibly just cut out the section of damaged plywood, cut out a hole in the foam and install some extra storage space up front? Picture of my idea is below ..... If I was able to do the picture below without any loss of strength in the boat, than would I need to do any extra bracing? the white box in the middle is my live well, and there is actually a piece of plywood that goes over the live well and expands back toward the console where a swivel casting seat is mounted also.

I look forward to any help or suggestions that anyone can give me on this ...

Thank You

 

[reelfishin]

Re: Foam Expanded, not too sure how too fix?

I'd make real sure that those cracks were caused by wet foam freezing and thus expanding.
Otherwise, you can cut out that panel, either ad a storage compartment or refoam and replace and reglass in some new wood.
Those boats were notorious for wet foam and rot.
The foam also serves some structural purposes in that boat.

 

[ragu78]

Re: Foam Expanded, not too sure how too fix?

thanks for the quick reply ...

I'd make real sure that those cracks were caused by wet foam freezing and thus expanding.

If it was, then what problems am I looking at? How would I also go about checking if it was? I had the boat out just about every weekend last year fishing and never had any water in my boat at all, I even propped up the front of the trailer and left it sit a few times to see if any water ran to the back of the boat and it was always bone dry ....

Otherwise, you can cut out that panel, either ad a storage compartment or refoam and replace and reglass in some new wood.
Those boats were notorious for wet foam and rot.
The foam also serves some structural purposes in that boat.

So maybe I shouldn't put in any storage compartments then? Also, If I replace the wood should I reglass over it? of can I skip that part seeing as I have never reglassed before?

Thanks again for the reply ... greatly appreciated!

 

[reelfishin]

Re: Foam Expanded, not too sure how too fix?

I'd check that boat real well for wet foam, wet wood and any other water intrusion damage. Those boats were at the very least very susceptible to rain damage and wood rot. Do a search here for wet foam, rotted wood, etc.
There's hours of reading.
If it is simply that one area, I'd most likely refoam and replace the wood, then glass it back over just as it was. A good way to see if the boat is retaining any water is to weigh it. If it's off by too much from the factory weight, then it's most likely soaked up a lot of water over the years. The only older Bayliners I've seen that survived so far were garage kept and never saw rain or wet weather. Their few and far between. They were ok boats if super well maintained but they weren't built with the best methods or materials. They were a lower entry level boat.

 

[ragu78]

Re: Foam Expanded, not too sure how too fix?

OK thx for all help reelfishin, it's greatly appreciated! Thankfully this boat only needs to last me one more season of fishing and then I'm buying a new boat ... of course I guess I cant complain for only picking up this boat for $1000 and getting at least 3 years of fishing out of it with no out of the pocket money on repairs until now lol.

 

[reelfishin]

Re: Foam Expanded, not too sure how too fix?

To be honest with you, if that were mine, I'd patch up the cracked wood with a layer of resin and glass mat and recarpet it if you plans are only to move on to another boat soon. The tops of the benches aren't structural and chances are it's been that way since day one.

I would want to know however the condition of the hull and it's flotation. If it is rotted and wet, I'd be looking to retire it now, a wet, rotted hull is not safe. Do you see any signs of wet foam? Take a core sample with a piece of tubing down into the foam.

 

[ragu78]

Re: Foam Expanded, not too sure how too fix?

Darn, wish I would have thought of taking a core sample with a piece of pipe like you said lol. Good news is I was able to remove the whole piece of wood without damaging it thanks to the help of my mitabo, then I cut out a nice square of foam right don't to the hull and it looks real good surprising. No rot or any wetness in the foam or hull bottom. So I replaced the foam and trimmed down the high spot, traced out the old piece of wood with some new wood, then resined and fiber matted it all back up. Came out looking brand new and I really impressed myself with having never done this before lol. Too be honest, I have too agree with you, I think it was like this from day one and was just shotty work from the factory.

Again reelfishin, I greatly appreciate your time, help and replies! So Thank you very much.

 

[BWR1953]

Re: Foam Expanded, not too sure how too fix?

So let's see the repair pix!

-BWR