DIY propane storage locker?

R

rapscallion

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The propane locker on the aft deck of my Carver 3007 needs replacing. I'm considering building my own rather than buying one. Has anyone here ever built a propane storage locker? Does anyone have the ABYC standards?

The existing locker appears to have been made from plywood painted with epoxy paint. From a DIY standpoint, I see possible materials options as:

- King Starboard (expensive);
- plywood coated with epoxy and painted;
- plywood with fiberglass and resin, then painted.

Other ideas? Painted aluminum?

Thanks!
 
plywood with fiberglass and resin, then painted

The glass will aid in abrasion resistance. Epoxy is hard and shatters. By adding glass to the mix you increase it's ability to flex from contact, and prolong the useful life. It is -always- better to use a glass layer, even if it is a very thin sheet if fine cloth. ( This includes even when you are glassing a fine veneer w/ clear epoxy. The glass "disappears" once wetted out. )

I suspect that you would have a difficult time getting the Starboard to a) be gas tight and b) stay that way.

See also: ABYC Propane standards. ( This is a downloadable PDF )

Note esp. Sect A-1.8
 
IIRC, Capt. Bill just built one on a yacht. He may be able to get the standard.
 
Thanks! Most helpful.

I agree that fiberglass is the better material to use. I may try a foam core to keep the weight down, if I can get my hands on some Divinycell.

Thanks again.
 
Food for thought:

If you use plywood w/ glass/epoxy, then virtually all of the strength comes from the wood, and the glass is simply an anti-abrasive and the epoxy is a water seal.

If you use Divinycell, then you will need to build up enough glass so that the strength comes from the cored glass/epoxy composite.

Personally, I'd use wood, w/ glass/epoxy, but either method would be effective. Just guessing, but in this size range, I suspect that the wood might actually be lighter. YMMV. Choose the system you are comfortable with, as I do not think the difference between the two systems will be great.
 
King Starboard will give you a better finish and will be much easier to build. Use 3/4 inch Starboard for strength.
 
If your gonna use Plywood, I would recommend using Marine plywood. Water or moisture intrusion through the fasteners will take its toll. I re-built some seating bases a few yrs back using "exterior grade" plywood, covered in glass, epoxy and UV stable paint. Its been 5 yrs and I need to repair them.

I may use a welded Plastic assembly this time? I will decide in a few months.
 
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