Instructables

Cozy Boat Episode 2: A New Skin

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The Cozy Boat finally needed a new skin.
Seagull poop ate holes in the cotton denim skin. Then the seagulls pecked at the holes to see if it had tasty guts. They pecked right through the closed cell foam layer. Now you couldn't use the boat at all without getting a wet butt.
Ray and Chloe volunteered to make a new skin.
 
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Step 1: Old and Broken

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Here's what the old skin looked like. It lasted a few years, but the seagulls were wrecking it.
Peel it off, exposing the closed-cell foam layer underneath.

Step 2: Patch the Big Hole

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Chloe uses an electric turkey knife to cut the hole cleanly into a spear shape.
Then she cuts a piece of foam to match the hole and glues it in using DAP weldwood contact cement.
In this case we didn't follow the directions and glued it in while the glue was still wet. The shape holds it in place and it would have been impossible to insert the plug after the glue got tacky.

Step 3: Patch the Stems

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The foam at the stems had separated. I guess I didn't make the foam layer big enough. We added a gore of thick foam, then Ray measured and cut a thin foam layer to glue over the top. This time we followed the directions and let the contact cement get tacky before pressing the parts together.
Then I used the turkey knife to smooth the edges of the patch.

Step 4: Check the Tarp for Holes

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I scavenged some gym floor covers from MIT to make the boat skin. Ray and Chloe hold it up to the sun to check it for holes. Looks like some revellers in high heels had put a few holes in it. We marked the holes with Ray's silver sharpie marker.
Mikeyfl1 year ago
Well done, a nice job, plus you have a lovely assistant that can Row while you relax
Foaly74 years ago
You could potentially use the tarp as a skin to begin with and not have to replace it later, right?
dla8884 years ago
As kids we (the neighborhood kids) used an old plastic bathtub as a boat. It was real easy to use once you got the hang of it.
macrumpton4 years ago
You might want to try a technique from modern skin on frame kayaks and apply a Dacron skin which can be heat shrunk with a heat gun to fit, and then coated with a sealant. It would give you a tauter smoother skin and the sealant would take care of any lashing holes.
I love it as much as those kids do. (Hopefully they don't hate it, and then the step title has to be changed.) +5/5 stars.
gmoon6 years ago
Ah, nice! I'm "fav"ing this one, and taking notes--I've got an old Klepper, but the skin is shot...
Very Cool! Great Instructable!