Building the mold for the urethane foam.

The foam is incredibly strong, considering it weighs so little.  The force of expansion popped out some of the screws that held the mold.  No problem, too much foam is easily sanded away in minutes.

In this picture you can see the glass and filler covering the factory exhaust holes.  Since we purchased Sunny Ray we have glassed over 14 factory holes in our boat!!!  Holes are just simply not good things in boats.  We almost sunk due to a through hull failure in the Gulf of Mexico, so I am happy to seal up any unnecessary holes.

I decided to use filler over the foam to help the shaping process and to aid in sealing the foam so no water works it's way in over the years.  The sanded and shaped filler will provide a good base for the layers of biaxial glass which will come later.  The rail along the deck will be screwed into base plates not allowing the screws to penetrate the deck Nidacore.  The base plates are pre-drilled, bored out and filled with epoxy.  After the glass and gel coat work is finished I'll re-drill the holes only deep enough for 3/4" screws so the watertight deck will not be compromised with screw holes.