1993 Caravelle foam and floor questions.

[firedog11ku]

Okay, so I recently bought this boat. Had some great help already with the drive already. I thought I was going to have to do a complete rebuild on the hull, but I got lucky. The floor was trashed. Had waterlogged wood between the fiberglass on the floor. Started by taking out the floor. Foam was wet, so I started to remove it along the stringers. Surprise surprise, the stringers are solid and fully intact.

So here's my question: can I remove just the foam that is wet and put new foam on top? It's wet on the top inch only. Can I take it down two inches and then put in new when I do the floor?

Thanks guys.

 

[Bomber Goober]

Re: 1993 Caravelle foam and floor questions.

Have you drilled 1/8" core sample holes in the stinger every foot or so to confirm they are good? Sometimes what can appear to good wood can be rotted or starting to rot. The same should be done down low on the transom from the inside. Be sure not to drill all the way through the hull though. About an 1" should be good. Now is the best time to be absolutely sure the stringers and transom are good before laying down a new deck.

As far as the foam goes. I wouldn't keep any of that foam in the boat. While it may not be completely waterlogged, it still can have moisture in it that wont dry out. Depending on the size of the boat you should be able to refoam using a 2 part expanding closed cell foam for about $130. Cheap considering what moisture retaining foam can do to the sub structure of your boat.

What kind of boat? Size? Got any pictures?

 

[Woodonglass]

Re: 1993 Caravelle foam and floor questions.

Have you core sampled to foam all the way down to the bottom of the hull?

 

[firedog11ku]

Re: 1993 Caravelle foam and floor questions.


Its a 1993 Caravelle with a 3.0 liter merc.

I took the foam out the height of the stringers about 6" wide. The foam was dry other than the to inch from the rear seat (parallel to the belt drive on the motor) to the captains seats. When the previous owner replaced the seats, they did nothing to seal their screw holes. That's where all the moisture was. I did plan on drilling a couple of cores in the stringers to make sure, though.

On a similar note, which foam should I use? I see that US Composites carries 2, 3, 4, Lbs varieties.

 

[Bomber Goober]

Re: 1993 Caravelle foam and floor questions.

View attachment 193108On a similar note, which foam should I use? I see that US Composites carries 2, 3, 4, Lbs varieties.

I used the 2lb on mine and I believe that is what most people use. I supoose you can use the 3 or 4 if you wanted more stiffness but I personally didn't see a need for it. With the 2lb and a 1/2" deck I don't have any flex in my floor at all.

Edit: BTW, Sharp looking boat.

 

[firedog11ku]

Re: 1993 Caravelle foam and floor questions.

Woodonglass: I did take the foam out all the way to the hull from the windshield to the transom. The only moisture was in the center where the new seats were installed. And the only moisture was about an inch below the old deck.

The old deck was solid, but I had to investigate the water damage to the deck once I removed the carpet.

I have no issue in removing the foam, just hate to do it if what's there won't be a problem. If I need to remove it, how much foam would I need for an eighteen footer?

I must say that being a firefighter I am curious to see if the damp foam will burn, and if so how well. It's the Pyro/investigator in me.

 

[Woodonglass]

Re: 1993 Caravelle foam and floor questions.

I'm confused. You say you took the foam out all the way to the hull from the windshield to the transom. And then you say you have no issue in removing the foam. Is the foam out or not?

 

[firedog11ku]

Re: 1993 Caravelle foam and floor questions.

Thanks Bomber Goober. The looks are what suckered me into buying her(not unlike my wife). All and all looks like a well made boat.

BTW, thank you for your service. Its guys like you that make it possible for the rest of us to "complain" about our boats.

 

[firedog11ku]

Re: 1993 Caravelle foam and floor questions.

It took out a strip about 6 inches wide, the length of the stringers from the windshield to the transom. Sorry I'm not so good at explaining things. What I type, makes sense in my head, but may seem a little murckey to those not in my head.

 

[firedog11ku]

Re: 1993 Caravelle foam and floor questions.

Sorry...yes, most of the foam is still in the hull.

 

[Woodonglass]

Re: 1993 Caravelle foam and floor questions.

Ok, I gotcha now. If there was NO water at the bottom of the foam/hull and if you core sample the stringers and transom and they check out good then, I'd use the 2# foam to replace what was removed and follow the instructions in my link on how to replace your deck.

 

[firedog11ku]

Re: 1993 Caravelle foam and floor questions.

Awesome. I don't know how DIYers like me ever got along without forums like this. Guys like you are what make this site the best.

Thanks for all the help.

 

[Woodonglass]

Re: 1993 Caravelle foam and floor questions.

Oh by the way, THANK YOU for your Service to your Community!!!!

 

[Bomber Goober]

Re: 1993 Caravelle foam and floor questions.

Oh by the way, THANK YOU for your Service to your Community!!!!

+1 I've experienced things most people could never imagine. However willingly going into something that is on FIRE, you have my respect brother.