After laying new carbon fiber cloth on both interior sides of the bow, which stiffened the hull and gave it integrity again, it was time to follow through with setting the blue XPS foam. I had tried cutting the foam with a razor knife, a hand saw and even a kitchen knife. Of those three the kitchen knife was easiest to work with to get a clean cut. However, I spent $20 on a hot foam cutter through Amazon and got my best results. None of those little blue styrofoam balls and relatively easy to cut complex curves. You definitely want to wear a respirator. The fumes are nasty.
All in all, I figure I added about 2 ounces of foam to the weight. I left a little gap on other side to ensure I was not spreading the hull and ensure the top would fit.
Hot Foam Cutter
Dry Fitting Foam
Foam Inset by Repaired Crack
Phase 1 of Returning the Top Nose
Since I also needed to repair cracks in the hull under the seat, it was decided to simply add a deck plate with access cover instead of returning the carbon patch. The deck plate cost $15 from West Marine and the hatch will be utilized to attach a small storage bag. The plate is made from ABS plastic, heavier and stiffer than carbon, so I think it will actually stiffen the area of the hole, though it added a few ounces as well.
Since I've lost 4 pounds, we're in good shape!
Stay tuned as we prepare for the Swimming Pool Test.
