Well, the time came that I needed to redo the foam on the Surfjet. The board weighed in (with 1/2 gallon fuel) at 183 pounds. This is about 45 pounds more than it was supposed to. I tried to extract the water from the foam using a vacuum pump but this was a futile attempt and I should have saved the money I spent on fittings etc.
Cutting the board open isn’t that hard…used the circular saw set to 3/8″ as suggested to avoid cutting into the hydraulic throttle tubing. This would have worked had the tubing been in the right place…as it was there was no way to avoid it and I ended up cutting through my brand new hose assembly…..ouch.
The pictures shown are my current progress. The ordering of the pictures is off for some reason. I have to redo the fire extinguisher housing, it was rotted out. The original was a cardboard tube they fiberglassed over. I opted to try some 4″ sewer tubing, making a mounting flange out of some stiff foam board. The same foam board will be used for the end cap as well. As long as I can get the angle right it should work out. The foam, when replaced, should hold it firmly in place.
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When I cut the top of the board off it delaminated. There is a layer of corrugated cardboard in the middle. I used the fiberglass epoxy, mixed with some Cab-o-sil, to glue it back together. It took 8oz of epoxy for the whole piece but seems pretty sturdy. Hopefully I didn’t change the contour too much…I guess I will find out later!
