UPDATE:
So I finished foaming up the deck. Used up 2 gallons of the 2lb density (USCG) foam kit. Took one gallon foam kit to fill each side (port, stbd.) which netted an area of ~10 cubic feet of expanded foam per side. So I have a total of around 20 cu-ft of foam under the deck. Took a little practice to get the hang of it, overall it went really well. I have the boat on a good incline that let the foam run down towards the stern, and just worked my way up the deck letting gravity do the work.
I also have the fuel tank reinstalled, and hooked up the new fill & vent lines. It's all pre-wired as well. I used 1/8" silicone rubber w/ adhesive backing (free scraps from work), and stuck them on the belly of the tank before I dropped it in place. It is very low durometer (shore 10 or 20A) which is quite soft and tacky, providing a little cushion and space underneath for moisture to drain away. I anchored it in place with three 1/4" s.s. lag screws on each end coated w/ 3M 5200.
After that I worked on the tank floor replacement section. I constructed this from 1/2" BC sanded ply, with 3/4"x1.5" poplar reinforcement bracing. I doubled up the 1/2" ply on the rear half section for I will install a recessed access port in that area. I finished off the underneath with a layer of 1708 biax.
Right now the floor section is ready to be glassed in place, and the floor to be leveled out smooth and gelcoated. Before I do that I want to get the cuddy-cabin bulkhead pieces tabbed in place, as well as the fuel fill hose pass-thru area located at the transom.
That’s all for now. Pics to follow.
