Need help with my sink to cooler project

[giantfan]

I am removing the sink behind my helm seat and want to make it into a cooler. I have never done any fiberglass work before and I am asking for some advise on how to proceed.

The existing sink is an insert that I have already removed from the boat. I am thinking of cutting out the existing sink from the insert and using the existing flange to attach the new cooler to.

I am a carpenter by trade and my plan is to make a box out of marine plywood and attaching it to the rim of the existing sink. I want to insulate it and thought that I would use closed cell rigid foam insulation between two plywood boxes that I will fiberglass inside and out. I have posted a rough drawing to show what I am proposing. It is a PDF file at the bottom of the pictures. I would like to make the box aprox 17" deep with a drain in the bottom.

One of my biggest concerns is the finish of the inside of the cooler. How can I make a smooth finished surface (something like gelcoat) on the inside of the cooler?

Am I pissing up a rope with this idea? Should I just get a fiberglass shop to make this for me? Should I build the box like in my drawing and send it to a shop to have it glassed and gelcoated? Can I do this myself?

If you think I should go the route of using a fiberglass shop, can anyone recommend one that would do this sort of thing and a rough idea of what something like this would cost?

Below are a few pictures of the sink area on the boat and the sink insert that I have removed to give you a better idea of what I propose to do. I have also attached a rough drawing of my plan for the plywood box which you will have to open as it is a scan from my computer in PDF format.

Any suggestions would be a big help as I have no idea if this will work.

Thank you in advance.

[clt_capt]

You can easily fiberglass over a plywood box and it will work great. If you are interested in doing a bit more fiberglass work, just build the box out of rigid foam (no wood) and fiberglass over that. It will be lighter, but will need a few more layers of fiberglass. Make the flange solid Fiberglass.

If the rigid foam you are talking about is pink board or blue board, you will need to use epoxy, as polyester will eat the foam.

Once you get it glassed, you can fair it out with epoxy mixed with microballoons - then prime and paint (or gelcoat)

Getting it smooth and shiny is all about the effort you want to put into it.

[giantfan]

Thanks for the reply.

Not having to do the plywood will save a bunch of time. Would the west system be a good way to go? Would that work with the insulation?

I know the finish is all about the prep. I just didn't know if I could do it myself. I was thinking about using the stuff they sell in Home Depot for refinishing tubs. I used it on a tub a couple of months ago and it gave the tub a nice finish. I don't know how it would hold up to putting cans and ice in there?

What paint would you recommend? Do they make a gelcoat in a spray can????

[clt_capt]

West System is great to extruded styrofoam. The pumps make it easy to get the ratio right. Get the slow hardener.

I would fair the inside with Microballoons and cab-o-sil - the microballoons sand out easily, but the silica adds some toughness.

Polyester Gelcoat isn't going to cure on top of epoxy without a barrier layer. I have used Interlux Topsides Enamel for a similar cooler - it did fine.

Thanks for the reply.

Not having to do the plywood will save a bunch of time. Would the west system be a good way to go? Would that work with the insulation?

I know the finish is all about the prep. I just didn't know if I could do it myself. I was thinking about using the stuff they sell in Home Depot for refinishing tubs. I used it on a tub a couple of months ago and it gave the tub a nice finish. I don't know how it would hold up to putting cans and ice in there?

What paint would you recommend? Do they make a gelcoat in a spray can????

[giantfan]

Thank you very much for your info.

It doesn't sound like such a big project to me anymore and I have always wanted to try my hand at doing some fiberglass work.


Ted

[clt_capt]

You will want to use fiberglass cloth, and not chopped strand Mat with epoxy - the binder in the mat doesn't dissolve correctly with epoxy.

If you don't have a fiberglass supply near you, try US Composites - www.uscomposites.com - I've had good luck ordering from them and their prices are quite reasonable.

Also take into account the thickness of the fiberglass and fairing when building the foam box. Once you glue the box together, you can rough shape the foam with a surform file to round the edges. That will make the glass work a bit easier.

Thank you very much for your info.

It doesn't sound like such a big project to me anymore and I have always wanted to try my hand at doing some fiberglass work.


Ted

[Finesse]

It doesn't sound like such a big project to me anymore and I have always wanted to try my hand at doing some fiberglass work.


Ted

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

[Agitated88]

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.

[Storm]

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

[dirtygirl sportfishing]

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?!!!!