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  1. #1
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    BostonWhaler console upgrades

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    using this Homedepot 1" Foam as core for the center console


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    Last edited by noli; 07-31-2022 at 04:51 AM.

  2. #2
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    bend foam with a heat gun

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    Last edited by noli; 06-14-2022 at 08:53 AM.

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  4. #3
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    I don't want gaps in the corners when using this foam core


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  5. #4
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    ...nice bend job...

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  7. #5
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    ...countour shape the top hard corners of the foam a bit, completely seal each piece of foam & let dry, embed it in cake frosting(bedding compound) with weights or clamps or what ever you have, let dry, scrape/sand the excess bedding compound, cover with matt...sand off all the little tits & bumps & cover again with one layer of whatever flavor glass you settled on...

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  9. #6
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    ...little 90 degree sander with roloc sanding disks on them work nice for small jobs like yours... (harbor freight?)...

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  11. #7
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    ...next time, search out some thinner core, for a console, like 3/8 or 1/2. the end result won't be any weaker...
    Last edited by FUJIMO; 06-14-2022 at 11:23 AM.

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  13. #8
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    sanded everything down ,


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    the core placement is almost done

    used cans to apply pressure on the corner rounded edges

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  15. #9
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    epoxy adhesion test , with no adverse reaction to thermal heat released



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  16. #10
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    glass over the foam core with epoxy

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  17. #11
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    vacuum bag prep , pressure drop test

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    Last edited by noli; 05-18-2023 at 02:23 PM.

  18. #12
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  19. #13
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    no observed bridging


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    .
    Last edited by noli; 05-18-2023 at 03:05 PM.

  20. #14
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    cutting the console for access


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  21. #15
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    mark the lines and cut the console


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