Coffin box rebuild

[dirtwheelsfl]

Got this thing off CL a couple years ago. Figure its time to get it on the boat!

All the foam is soaked, wood cores rotted, weighs a ton... I wont be reusing the liner but going to use the hatches and lips. There was probably about 1/2" of foam in the sides, gona put at least some 1" in there with a removable divider...



I guess they injected it thru these holes



Bottom cut



Liner flange cut



Separated. Glad the foam was soaked or else it would probably be almost impossible if not!



Fits nice!





Tabbed the bottom back on tonite... 

[dirtwheelsfl]

Well change of plans. Ditched the reusing of original hatches and frame, just as much work to rebuild em and I don't think theyd insulate as well as they need to...


Glued in some 1" Plascore and glassed. 2x1200 and some finish cloth (overkill but I want this thing indestructible) Rather would have used some foam but had the plascore already..



Expanding foam in the corners. (packing tape on a pvc pipe gave the radii)





1.5" threaded drain



Then after it stiffened up I cut the original flange off and started on a new lip/gasket surface. Routed out the plascore from the top about 1" deep and poured foam in the cavity between the skins, then blocked the whole box to make sure the top edge was even all the way around.









The sides are a lil wavy but I took out all I could. It was horrible when I got it..





New lid is some 2" foam I had laying around. Routed it out to mate with the lip and "core it" at the same time. Kind of a pain to glass! (2x1700 and 6oz)



Then ill cut the outside of the lid down to match the box sides and lay up the topside..

[CLM65]

Nice work, Chris!  What is your trick to get the glass to sit tight on the sharp bends?

[RickK]

Ditto on Craig's comment.

[dirtwheelsfl]

Fillet of thickened epoxy.  Then lots of rubber gloves to work it by hand.  Usually a paint brush too. And darts (slits) in the glass on corners. No darts on that lid layup though as i didnt want overlaps on the corners sticking up where the gasket surface is. Combination of a gloved hand and hard roller for that. Have to work from the middle outwards so the glass doesnt pull itself out of the inside corners. I was cussin on that one!

[dirtwheelsfl]

Got the top of the lid layed up.



Before/during that I glued in glass slugs for screwing hinges and latches to.  (don't let cabosil get damp, itll turn into lil rice pellets and drag grooves in your fairing compound!)



And routed a groove for thickened epoxy so the top skin had something to connect to the bottom skin with without having to round it over and wrap the edge



Glassed some pvc board divider holders in



Mocked up hardware and gasket





Old surfboard trick used for making a "padeye" I think they call em. Gona use these to tie some line to to keep the lid from flopping all the way over

[CLM65]

Sweet!

[RickK]

Looks like a refrigerator - nice work 

[Capt. Bob]

Looks like a refrigerator

Bet it weighs just as much.

I will state this.
Dirt, you do think outside the box.

[dirtwheelsfl]

She'll be about 105 when its done.  About the same as the girls i TRY to get onboard haha.    Boat really needs weight in the bow...

[RickK]

 

[CLM65]

She'll be about 105 when its done.  About the same as the girls i TRY to get onboard haha.    Boat really needs weight in the bow...

Maybe you should try for bigger girls!

[dirtwheelsfl]

Been trying to ween myself off of them for awhile now, its difficult!  Haha

[dirtwheelsfl]

Lil bit of fairing and paint and shes done!

Side note:  Not impressed with the paint I used for nonskid. Seems to stain and discolor pretty easily...

[RickK]

That thing is HUGE - you can sure store a lot of goodies in there. 
Have the wasps found your anchor locker yet?