Do you have enough room for the bunk supports brackets to move them outside the chine?
Looks like it will be tight moving them out, at least in the pic.
Adding more is not always the best idea, in fact more can cause troubles. More means more chances for lack of adhesion and water being trapped between a layer of sealer and the aluminum which will sooner or later cause corrosion. Gluvit epoxy over 5200 is not a good idea. 5200 is best used as a sealer/adhesive sandwiched between 2 objects not blobbed on over the top. Multiple layers of these products that all expand and contract at a different rate is a recipe for failure.
The above goes for the using a bed liner on the aluminum over the gluvit and 5200, way too many things to go wrong. Noise from a boat? To me, I can't think of any sound a boat makes that is noise. If your hearing is so sensitive that rigid foam board and plywood doesn't dampen sound transfer to where you need a little thin layer of bed liner then I suggest ear plugs. Especially since the outboard motor will make so much more "noise" than the wonderful sound of water rushing under your boat.
You're right pour in foam is not the preferred method of adding flotation. The cost and difficulty along with the blocking of water flow made me steer clear.
Bunks look good to me, should provide ample support. Only issue you may have with the bunks protruding out is they could be in the way of the stern eye and tie down straps to the trailer.
Yeah those stern straps don't have to be super tight, just snug that'll work fine.
I have the boat buckles on my SS and Chief trailers, they are the absolute most wonderful invention ever made for a boat trailer. The price of the SS models are a bit spendy but if you only have to purchase them once then it's worth it.
I had to fabricate a bracket for both my boats in order to use the buckles.
flour is an organic material
Fair point. Only mentioned it as I see people saying they using it with epoxy. With that being said, the question I should ask is:
Can you thicken Gulvit/Coatit or should I use it in natural form?
Just remember this is a Boat and not a car. The fiberglass and filler products should be for a MARINE environment. Cars don't spend that much time submerged in water so the products can be designed differently. Highly recommend you use Marine rated products. To thicken your epoxy you can use just about anything. Wood Dust from your sander, Baby Powder etc... Epoxy has much better water resistance so using non hygroscopic materials is not as important.
I used a piece of angle iron to attach the boat buckle to the back of the trailer frame tube. There's 3 holes I drilled before sanding and priming and painting the iron. One hole for the buckle to attach, 1 for the iron to attach to the tube and the other is a drain hole you can see in the first pic.