DIY structural foam (or honeycomb) panels
DIY structural foam (or honeycomb) panels
(OP)
I'm engineering a new boat floor for a customer's boat. He uses the boat very heavily and he's tired of replacing the flooring every few years and wants something a bit more permanent. I've discussed some FRP panels and some monocoque honeycomb skinned panels that would do well, but the cost of materials is rather prohibitive, as is supply when you're only buying two sheets. Here are some examples of things we found that might suit to give you an idea of where I'm going with this:
http://www.ayrescom.com/products/default.asp (specifically the 2016 material)
http ://www.fib erman.ca/s tructural_ insulated_ panels.cfm
Is there some way I can make some structural panels myself here at the shop? Concerns are weight, rigidity, and oil/gas resistance. The panels will be sealed from all edges, but if microfissures develop in anything down the road I don't want a the possible hydrocarbon introduction to eat the foam. For the same fissuring reason, I don't want the foam/honeycomb to absorb water. UV won't be much of a concern since we are going to coat the entire floor with Rhino liner.
http://www.ayrescom.com/products/default.asp (specifically the 2016 material)
http
Is there some way I can make some structural panels myself here at the shop? Concerns are weight, rigidity, and oil/gas resistance. The panels will be sealed from all edges, but if microfissures develop in anything down the road I don't want a the possible hydrocarbon introduction to eat the foam. For the same fissuring reason, I don't want the foam/honeycomb to absorb water. UV won't be much of a concern since we are going to coat the entire floor with Rhino liner.





RE: DIY structural foam (or honeycomb) panels
I.e., use FRP bar grate to carry the load, and skin the top with thin stainless steel.
Mike Halloran
Pembroke Pines, FL, USA
RE: DIY structural foam (or honeycomb) panels
... but maybe some FRP bar grate with FRP sheet bonded to it
This is grate... I mean great. My knowledge of materials is a bit behind.
RE: DIY structural foam (or honeycomb) panels
fully linked PVC foam rather than Polyurethane foam has better resistance to water because it is a closed cell foam.It swells a bit in MEK but seems to do well in gasoline.These people sell small quantities.
ht
Pvc foam manufacturers are Diab and Airex.
I get the idea that this is a commercial fishing boat.
But I have no idea how big your panels need to be.
A disposable mold for floor panels can be made from melamine faced bathroom board.
B.E.
The good engineer does not need to memorize every formula; he just needs to know where he can find them when he needs them. Old professor
RE: DIY structural foam (or honeycomb) panels
I don't have the measurements in front of me, but the cabin floor (from bilge to helm) is about 8' long and the bowrider section is about 6' long. Width at the widest point is 4'-1" which is easily done with 4' material and 1/2" of filleting on each side.
Here is a photo of what it looks like right now (with the exception of the fact that the motor stringers have been completed.)
RE: DIY structural foam (or honeycomb) panels
RE: DIY structural foam (or honeycomb) panels
I think stiletto heels entered women's fashion in the 1960's, and immediately caused a problem with dents and even punctures in airliner floors. That problem has been solved. You might find usable exemplars in an aircraft junkyard.
Mike Halloran
Pembroke Pines, FL, USA
RE: DIY structural foam (or honeycomb) panels
The aft end of the stringers are doweled and epoxied to the transom. The front is currently tied together with a 3/4" plywood bulkhead as a temporary support until I finish designing the floor.
The original design was this way but it didn't suit me. I will be extending the floor the whole way back to the transom on either side of the motor stringers. The outsides of each of those stringers will be supported by a complete stressed-skin composite box
I did a super-quick, not to scale drawing of a general idea. Imagine those triangular supports continuing back on the left and right of the motor stringers, and the floor continuing as well.
RE: DIY structural foam (or honeycomb) panels
These are things you mentioned in your original post
If you are intending to put that pourfoam back in later,run a perforated drain tube at the lowest point to a sump drain. The stuff absorbs 2% of its own weight in water in a 24 hour period and over time will become a water sodden mess if water is allowed to stand on it.
B.E.
The good engineer does not need to memorize every formula; he just needs to know where he can find them when he needs them. Old professor
RE: DIY structural foam (or honeycomb) panels
I refuse to put foam back in. I've never pulled dry foam out of a boat floor. I never understood why some engineer at the factory thought it would be a good idea. I'm hoping to come up with a composite material that I can use to make this framework and flooring that can be epoxied in place to supplement hull rigidity, and at least lasts long enough to warrant the additional labor involved when replacing it down the road. I'm trying to make a floor that basically can't be damaged by other than physically destructive means.
We have effectively removed nearly all the wood from this boat and replaced it with other materials that won't rot. The floor is the last thing and then we should have a basically rot-free boat.
It would also be nice to be known as "THE shop" that does this kind of custom work, so its not just one boat that I'm trying to throw together. I wouldn't mind finding a material and developing a process so I can do this on other boats.
RE: DIY structural foam (or honeycomb) panels
Rubber mats over the floor will do a lot to prevent damage.
RE: DIY structural foam (or honeycomb) panels
Mike Halloran
Pembroke Pines, FL, USA
RE: DIY structural foam (or honeycomb) panels
RE: DIY structural foam (or honeycomb) panels
It was customary to put it under the floor and up under the gunwhales ( gunnels).
B.E.
The good engineer does not need to memorize every formula; he just needs to know where he can find them when he needs them. Old professor
RE: DIY structural foam (or honeycomb) panels
All you would be doing now is bonding the pieces together.
RE: DIY structural foam (or honeycomb) panels
If I exhaust all other options I'll go back to considering wood substrates.
RE: DIY structural foam (or honeycomb) panels
Mike Halloran
Pembroke Pines, FL, USA
RE: DIY structural foam (or honeycomb) panels
Pre butter the foam with a mixture of resin and Glass micro spheres for better adhesion of the faces.
B.E.
The good engineer does not need to memorize every formula; he just needs to know where he can find them when he needs them. Old professor
RE: DIY structural foam (or honeycomb) panels
I meant to say 1/8" on the top face,and 1/16" on the bottom face.
B.E.
The good engineer does not need to memorize every formula; he just needs to know where he can find them when he needs them. Old professor
RE: DIY structural foam (or honeycomb) panels
RE: DIY structural foam (or honeycomb) panels
I am attaching a link to their specification brochure.
ht
B.E.
The good engineer does not need to memorize every formula; he just needs to know where he can find them when he needs them. Old professor