Need to replace cabin walls on party hut pontoon

WVToon

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Just started a tear down of a 1997 sun tracker party hut with 10ft cabin enclosure. Like many the cabin walls are rotted and water logged. I'm trying to determine a good option for replacing the walls which are 1" thick and mounted in aluminum H channel. Trying to find something that is both light, waterproof and 1" thick in 4'x8' sheets is proving difficult. I found a composite fascia board type material but it's not 1" thick. I did find an insulated aluminum panel which would be perfect if not for it being $316 a piece plus shipping. I will need approximately 8 sheets, maybe more if we extend the cabin to enclose the rear of the boat which is currently open. If anyone has a source or ideas on wall replacements please let me know. We are pretty much at a stopping point on this rebuild until we figure out these walls. Thanks for any and all info!
 

Bondo

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I'm trying to determine a good option for replacing the walls which are 1" thick and mounted in aluminum H channel.

Ayuh,..... Welcome Aboard,..... What materials are the originals,..??
 

WVToon

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Ayuh,..... Welcome Aboard,..... What materials are the originals,..??
Originals were a white strofoam type material skinned with a thin wood and fiberglass sheet. Very very poor design so not going to use the same to replace. The party huts are infamous for rotting deteriorating walls. Ours were completely water logged and rotted with cracks through out.
 

Bondo

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Ok,.... Look up FRP panels, 'n rigid foam insulation of the appropriate thickness,...

Dow blue board insulation panels can be used underground, so it's as water proof as it gets,...
The FRP panels are what's used to line "Clean Areas" that are constantly bein' washed down,....
Hospital ERs, 'n slaughterhouses,....
 
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