Re: New project opportunity
I am working on a project boat for my wife. Replacing the deck, filling the core with foam (it's an old BW that was scraped out), and putting in seats. It's a small 11' skiff, and she wants her 15hp Nissan on it. I used pour-in foam, as per the salesmans suggestion, then leveled off the foam with a sander/grinder.
He suggested a hand saw, but it wouldn't cut it, kept binding in the foam. The deck is made up of 1/4" foam sheet, covered with chopped matt/woven roven/chopped mat on both sides for strength and light weight. It's also cheaper than marine plywood.
He told me to put the foam in 1st because if you don't do it right, after the deck is in, it can distort, even destroy the boat when it expands.
So far its working out fine. I would suggest using diab (plastic honeycomb with a scrim on both sides) for your deck as it is lighter still, and very strong with the glass overcoat.
You project looks like it will be fairly simple and straight forward.
How's the transom?
Luck
Bob