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camman73

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I'm looking for sources for structural foam board for rebuilding our engine hatch cover.

I have found Jamestown and Defender carrying core-cell in the size I need (3/4" thick x 48" x 48") but am having trouble finding any of the other viable foam boards in the size I need (divinycell or klegecell). Defender wants $150 just for shipping.

Can anyone point me in the direction of a distributor that might carry these? Someone within driving distance of Chicago would be great to save on shipping costs.

Thanks in advance.
 
Just use 3/4" CDX Plywood. My hatch is 4X6 and it works fine with simple gas lifts.

paint all surfaces with 2 coats epoxy unthickened, then fill edge voids with thickened epoxy. Then cover top surface with roving and epoxy. Finally paint all surfaces. I used epoxy bottom paint cuz it's tuff. Sprinkle anti-skid stuff between coats.
 
I also like the divinycell, but remember, it does not hold screws. You must install wood where the screws will penetrate the lid.
Sorry, I do not have a supplier.
 
Plywood is heavy and rot, foam core weighs nothing

I did too 48" x 20" hatches with 5/8 divinicel and 3 layers of 10 oz S glass, and a 1" strip of epoxied foam around the bottom edge. Very light and stiff

No idea who would sell it up in your area though, i order it from west marine megayacht, I wonder if your local store can special order it as well.
 
quote:
Originally posted by GSENT

I also like the divinycell, but remember, it does not hold screws. You must install wood where the screws will penetrate the lid.
Sorry, I do not have a supplier.

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Yes, the old construction had a 5" wide strip of plywood outside of the foam center section, was just going to recreate this.
 
quote:
Originally posted by PascalG

Plywood is heavy and rot, foam core weighs nothing

I did too 48" x 20" hatches with 5/8 divinicel and 3 layers of 10 oz S glass, and a 1" strip of epoxied foam around the bottom edge. Very light and stiff

No idea who would sell it up in your area though, i order it from west marine megayacht, I wonder if your local store can special order it as well.

Click to expand...


Agreed, may be forced to go with plywood or balsa core. Having a heck of a time finding this stuff local and shipping is more then the board from the out of state places I have contacted. The places that do have it locally only sell it by the case.
 
There was a place in NJ that used to supply to Silverton and the other NJ manufacturers. Mahogony Company. Google 609-476-6400 and about 6 down is the website. At least you could look up the manufacturers and see if there is a distributor closer to you. Been at this place and it's impressive. I dumpster dove for balsa scraps I used for little projects a few years ago.
 
I'm already emailing with the sales manager for Diab, the manufacturer of divinycell. The only place he suggessted 2 hrs away that sells it by the sheet closed their doors 6 months ago.
 
What about a REAL building supply company; i.e. not a big box store.
 
Seems Pascal has a poor regard for plywood. If constructed properly, it'll last as long as any thing else.

Just curious, why are you replacing the divinycell??
 
I can ship from FL to Waukegan for $100. It is only available here in 4x8. I think it would be a little too vulnerable for transit without some kind of crating so the $150 may have been crated, maybe not. If forced to buy 4x8, I would still recommend cutting in half for easier, safer shipping. If you can't resolve this with cheaper logistics, let me know and I'll see what costs are. I'll need to know the schedule (H30, 45, 60, 80) you wish to use.
 
Charlie

Yes ply can last (as long as water doesn't get in...) but it is a lot heavier.
 
quote:
Originally posted by jtybt15

Seems Pascal has a poor regard for plywood. If constructed properly, it'll last as long as any thing else.

Just curious, why are you replacing the divinycell??

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It wasn't divinycell, it was some brittle blue foam, probably original from 20 years ago.

Bayliner didn't seal the through bolts for the hinges and the pulls so water go in an rotted the plywood around the perimeter of the hatch. No way to seperate the skins to replace the plywood without also destroying the foam.
 
quote:
Originally posted by Rub Rails

I can ship from FL to Waukegan for $100. It is only available here in 4x8. I think it would be a little too vulnerable for transit without some kind of crating so the $150 may have been crated, maybe not. If forced to buy 4x8, I would still recommend cutting in half for easier, safer shipping. If you can't resolve this with cheaper logistics, let me know and I'll see what costs are. I'll need to know the schedule (H30, 45, 60, 80) you wish to use.

Click to expand...


Thanks for the offer, $100 - $150 shipping is what I am finding from out of state sources. Hate paying as much in shipping as the actual product. I know the retail market is probably just a blip on the radar for Diab but it would be nice if they had better retail exposure within 500 miles of Chicago.
 
Can't you remove the rotten ply with a multimax tool (dremel or similar) and then insert replacement bedded in thickness epoxy?
 
quote:
Originally posted by PascalG

Can't you remove the rotten ply with a multimax tool (dremel or similar) and then insert replacement bedded in thickness epoxy?

Click to expand...


If i could have seen inside before taking it apart this might have been an option. Didn't even know there was foam in there until I started taking it apart.
 
I would look for Marine Grade Plywood. That Or White Oak. But that is me.
 
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