Need help with my sink to cooler project

[RCARNEY]

Not aware of gel coat being in a can. I do not believe that mixing MEKP and gelcoat would live in a can with out going off. Wet sanding is a given when using gel coat to get your smooth and shiny finish. I think that I would go with awl-grip as you can spray after using primer and watch it shine. Good luck.



www.cyntinory.com

[giantfan]

Ted, 17" deep? Just a thought, but what about adding a 1/4" ledge around the inside about 10-12" from the bottom...that way you can install some sorta tray to hold the items you don't want sitting on the ice? Just a thought.

That's a great idea but this cooler will be used for nothing but drinks. I have a bait cooler with a tray for my dead baits and I use the fridge for all the food.

You might want to consider using Coosa panel http://www.coosacomposites.com. Basically, Coosa is a lightweight composite foam cored panel sandwiched between fiberglass. It is sold in 4'x8' sheets and in thicknesses of 1/4" to 2". Once assembled, you would still need to add a sealer topcoat. The downside to Coosa is the price. It comes in three grades. For your application, you wouldn't need the strongest grade since it won't be supporting anything. If you use 1", you would already have sufficient insulation built-in.

I'm currently building a galley out of some 3/4" Coosa. I went w/ the mid-grade which is a bit cheaper. I'm also building an icebox w/ 1" panel.

I haven't decided what I will use for a topcoat. Topcoat will either be fiberglass and gelcoat or epoxy w/ two part linear polyurethane paint.

Storm

Is that the stuff they make walk-in boxes out of?
Sounds like that could be a good option. I have the rigid insulation already... just pulled some off of one of my jobsites, I am using the stuff that they put under flat roofing. Its pretty tough and has a good R value.

[CSS]

GIANTFAN, minicraft of florida makes an aerosol gelcoat .they make it to match alot of boat manufacturers factory gelcoats, i ordered some to match my original mako color. it comes with a aerosol can of gelcoat and pump to pump catylist into can and then you can spray i cant tell you the results as i havnt use it yet just do a search for minicraft of florida dont know if you would be interested just thought you could check it out, also not sure of the coverage of one can i just have afew spots to touch up.

[giantfan]

hey Giant,
That sink will work great in my rigging station let me know if u want to sell it, I am in Northern MD and if you want to make the trip down there I can help yu out for the day I have foam or you can use wood and polyester resin, just an opinion, why would you use epoxy if the whole boat is made of polyester resin ???Just an offer if you are a little intimidated by it and at no charge??!! Just tryin to help a fella out even if he does like the Giants?!!!!

That's a very kind offer. Thank you very much.

I was going to use the rim from the existing sink to attach the cooler part to and glass over the entire thing. I don't think that I can really make it down to Md in the near future.... when the wife doesn't have me doing something I will be working on the boat. If I came down to Md it would turn into a long weekend as there is no way I could go down there and not visit a few close friends.

I don't really know how to match that rim without cutting the sink out and using the existing rim.... If you can come up with something that would work you can have it. The new one has to be the same due to the fact that the top cover has bumpers on it that actually sit on the rim of the sink.

The reason I brought up the West system is that I already have a bunch in my shop and I have used it in the past as a glue and it worked great. Is there a problem with using it? The cooler will be under the hinged top that is existing and the only time you will see it is when it's open so I'm not really worried about it matching exactly. I just want it to be well insulated, strong and not look like it came out of a high school shop class.

[giantfan]

Thank you everyone for all the replies. This is such a great site.

I ask so many questions and am not able to give many answers.

You all ROCK!!!!

Given the quality of some of the projects / work you've posted ... I think you'll do fine .... If you need some help give a shout

Thanks for your kind words, I got your PM but I was tied up in meetings all afternoon and didn't get a chance to give you a shout.... can I call tomorrow?

GIANTFAN, minicraft of florida makes an aerosol gelcoat .they make it to match alot of boat manufacturers factory gelcoats, i ordered some to match my original mako color. it comes with a aerosol can of gelcoat and pump to pump catylist into can and then you can spray i cant tell you the results as i havnt use it yet just do a search for minicraft of florida dont know if you would be interested just thought you could check it out, also not sure of the coverage of one can i just have afew spots to touch up.

Sounds pretty cool. I will give it a look.

Thanks.

[clt_capt]

West System is great stuff - as far as epoxies go, it is pretty forgiving in the mix ratio - especially if you use the West Systems pumps or measure carefully. If your box is made of styrofoam, you really don't have any choice but to use epoxy.

Most likely you will need to paint it, because Polyester gelcoat will not cure properly on epoxy without a barrier coat of some kind.

Epoxy will bond to polyester, polyester will not bond to epoxy.

[giantfan]

West System is great stuff - as far as epoxies go, it is pretty forgiving in the mix ratio - especially if you use the West Systems pumps or measure carefully. If your box is made of styrofoam, you really don't have any choice but to use epoxy.

Most likely you will need to paint it, because Polyester gelcoat will not cure properly on epoxy without a barrier coat of some kind.

Epoxy will bond to polyester, polyester will not bond to epoxy.

Can I spray the Interlux Topsides?

If I use the old rim will the west system bond to it? There will be a lot of weight in there and with the pounding of the boat in rough seas it is going to need to be strong. I guess I could always support it underneath but that would take up some of my storage under there.

Oh and I do have the pumps for the West System.

Nevermind.... now that I looked again... you already answered the bonding question. Sorry about that. I hate being out of my element. Wood is all I know

[clt_capt]

I've only brushed the Interlux - but I imagine that with the right reducer, you could spray it. Awlgrip may be a tougher finish.

You can certainly bond the old rim to the new box with epoxy.

But you could probably build the whole thing from scratch - integrated lip and all...

Use the sink as a template, mark it on 3/4 foam, cut out the marked section and discard - now you have a form for the rolled lip. Center your foam box in the opening upside down and fiberglass it, allowing the fiberglass to extend across the gap and roll up the foam - this will create your lip.

Once you have the layers on, let it setup, then flip it. Rough up the top side of the lip and now you can glass the inside...

[Agitated88]

That's a great idea but this cooler will be used for nothing but drinks. I have a bait cooler with a tray for my dead baits and I use the fridge for all the food.

Sounds good Ted...oh yea, I had a chance to go back and look at that console you did on the Whaler, nice work!!

[giantfan]

Sounds good Ted...oh yea, I had a chance to go back and look at that console you did on the Whaler, nice work!!

Thanks,

It would have been much easier if I had waited two days.....

I cut the whole thing using the old console, which was left uncovered for years as a template..... two days after I cut everything I found a set of the original cut sheets from Boston Whaler.

I think next winter I'm going to build a Garvey Bay boat and see how I do with that.