Need help with my sink to cooler project

[Agitated88]

Thanks,
It would have been much easier if I had waited two days.....
I think next winter I'm going to build a Garvey Bay boat and see how I do with that.

Something like this? What size? Sounds like a fun project!

[Capt-D]

Number one thing to remember when glassing is that glass cloth does not like 90 degree angles, not even 3oz glass. Life will be a lot easier for your if all of your corners (especially the ones visible) are rounded (if even just a little bit) before laying on the glass. Being your first time, if you don't round the edges you WILL end up with raised pockets at the corners. Good luck and enjoy (especially the fairing).

-D

[giantfan]

Something like this? What size? Sounds like a fun project!

Exactly like that. Sweet job.

How long did that take?

Not sure on the size.... my buddy with the Whaler is talking me into it. We had a good time doing his console.

I think he said the 13'???? not really sure. We were also talking about the smallest one that has the phone booth looking enclosure at the helm. He was all chubbed up when we were at the decoy show in Tuckerton looking at all of the boats that were down there.

[Agitated88]

Exactly like that. Sweet job.
How long did that take?
Not sure on the size.... my buddy with the Whaler is talking me into it. We had a good time doing his console.
I think he said the 13'???? not really sure. We were also talking about the smallest one that has the phone booth looking enclosure at the helm. He was all chubbed up when we were at the decoy show in Tuckerton looking at all of the boats that were down there.

I wish I could take credit for that one Ted...but, when you said you were gonna build one I went searching and found it. I believe that one is 11', and the guy has a 9.9 on it. Now, once I finally leave the AF, I want to do a boat with my dad...but that's a couple years away.

[giantfan]

Number one thing to remember when glassing is that glass cloth does not like 90 degree angles, not even 3oz glass. Life will be a lot easier for your if all of your corners (especially the ones visible) are rounded (if even just a little bit) before laying on the glass. Being your first time, if you don't round the edges you WILL end up with raised pockets at the corners. Good luck and enjoy (especially the fairing).

-D

Thanks for the tip.... I was thinking that I would form some kind of transition between the bottom and the sides of the cooler out of the insulation with a rasp. I'm only planning on doing that from the inside. The outside will have 90* corners but I don't think that needs to look perfect.... you won't be able to see the underside of the cooler unless you open the door and stick your head in the compartment below.

Fairing.... I'm no stranger to sandpaper..... I'm not very good with a saw so I go thru plenty of sandpaper when doing wood work

[giantfan]

Ok.... so I just started cutting the lip off of my existing sink.

Got about 6 inches and went thru two jig saw blades.

What should I cut the fiberglass with?

[clt_capt]

DeWalt makes an 8TPI Aluminum/Fiberglass blade - It works the best of any that I've used. They aren't cheap, but they work. You can count on going through a few of them

I have also used a carbide abrasive blade - for very thick stuff - those blades were about $8 apiece...

[giantfan]

Thank you,

On my way to go and pick one up.

[giantfan]

Did some work on my project today.

I got the flange cut off, built the box, attached the flange to the box and rounded off all of the 90* corners with bondo.

I decided to build the box out of plywood.... I was shamed into going with a gelcoat finish by the guys down at the marina..... I will insulate the outside with spray foam after all is installed.

Below are some pictures.

How smooth does this need to be before I start the glass?

The close up is the worst spot.... just wondering if I need to go nuts at this point.... I am guessing that I will have plenty of sanding to do after the glass is done.

Is this good enough to start glassing or does it need to be perfect before I start the glass?

[clt_capt]

Bondo sands a LOT easier that fiberglass - and isn't as itchy

If you can smooth the ripples, you are less likely to get air bubbles in the corners. Just hit it with a detail sander with fairly coarse grit and you should be good to go.