Inboard cowling building

[Redrig]

hello all,

I have a 78 bell boy with an inboard and the original engine cowling is getting hammered, it is falling apart at the joints and looks like crap, I want to build another.

I will just use the current one for the dimensions and basically build a replica.

my Question is what type of material should I use for this ?

the old one is basically plywood covered with a wood grain type sheeting for the look.

anyone have some ideas of a strong, lightweight material that would be good for this build ?

Thanks

 

[gm280]

Re: Inboard cowling building

Maybe you could make a Styrofoam mold type cover (glue pieces together and sand to basic shape) after the old one and then lay a few layers of fiberglass mat and resin and make a fiberglass cowling. I believe that would last as long as you want it to... After you get a few layers of fiberglass and resin you then take some acetone or lacquer thinner or some type solvent and wash out the foam...wha la...cowling... Then just sand, paint or just leave it natural...

 

[Redrig]

Re: Inboard cowling building

that does sounds like a cool idea however, I honestly dont half know what of what you just said, I have never messed with fiberglass or resins or anything like that.

I do have a decent woodworking background and have a table saw, router for the edges, ect. everything to make a nice cowling. I was just wondering if there would be a preferred type of wood or laminate wood to complete this with.

would marine plywood be a good idea or is that overkill ? That stuff is stronger than standard ply right ?

 

[jbcurt00]

Re: Inboard cowling building

No reason not to mimic the old doghouse:

Exterior grade plywood, cut to match the existing, covered w/ fiberglass & polyester resin, epoxy (w/ or w/out fiberglass) and then upholstered w/ vinyl to match the boat's interior is a fairly common way to re-make the doghouse.

Marine ply is certified to have a void-free core, and is usually more thinner veneers then a similar thickness non-marine plywood. It is somewhat expensive. Good material to use though. What do you need 1 sheet?

Saving $20 on just 1 sheet may not be a priority, if it's $40 or 50 more expensive then Arauco or MDO, I'd consider 1 of those instead. The price difference will pay for the epoxy & upholstery supplies......

 

[gm280]

Re: Inboard cowling building

that does sounds like a cool idea however, I honestly dont half know what of what you just said, I have never messed with fiberglass or resins or anything like that.

I do have a decent woodworking background and have a table saw, router for the edges, ect. everything to make a nice cowling. I was just wondering if there would be a preferred type of wood or laminate wood to complete this with.

would marine plywood be a good idea or is that overkill ? That stuff is stronger than standard ply right ?

What I was saying is you could use your woodworking skills and make a copy of your old cowling but out of Styrofoam exactly like you would with wood. You can buy the Styrofoam at Lowe's or places like that in sheets and cut it out and sand it to the exact shape of the existing one. Then you cover that foam with fiberglass and resins over the foam. And after a few coverings of fiberglass mat and resin, it becomes solid as a rock and ready to remove the foam. The foam can be dissolved using the solvents I previously stated. In fact it dissolves that foam real fast. Ever try to put lacquer thinner in a Styrofoam cup? Doesn’t work does it? That is the exact same issue with the foam cowling too. And what is left is your new cowling. So your woodworking skills can make a fiberglass cowl if you want... I think you would be good at it too...