Building a Fishing Kayak Cooler #2: Sandwiching the Foam

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Blog entry by DustyMark posted 04-30-2019 05:32 AM 786 reads 0 times favorited 2 comments Add to Favorites Watch
« Part 1: The Design Part 2 of Building a Fishing Kayak Cooler series Part 3: Prep Work for Interior Fiberglassing »

The Approach

My plan is to make the cooler as light as possible without losing durability.

1” pink foam is sandwiched between the 1/4” outer shell and the 1/8” inner shell. 1/2” white pine is used to connect the two layers of plywood. I’ve added another layer of 1/4” plywood behind hinges or handles to give screws more material to bit into.

Foam is routed out around the areas where the extra plywood is located so that the foam lays flat between the layers of plywood. I’m even using scrap foam from displays I used at camp the past five summers!

Foam is in place.

1/2” pine caps off the foam.

1/8” plywood covers the foam and is glued to the 1/2” white pine. The extra layer of pine on the cross piece is for the hinges. This photo is of the final dry assembly before gluing.

I stapled, glued, and clamped the 1/2” pine to the exterior sides, but wasn’t happy with the results. I opted to clamp the interior assembly together without staples. Polyurethane construction adhesive is great for these type of projects since it’s easy to work with, is super strong, and relatively inexpensive.

Next Steps

The next steps involve laying down epoxy fillets in the inside seams and fiberglassing the interior.

-- Mark, Minnesota

2 comments so far

View robscastle's profile


7238 posts in 3010 days

#1 posted 04-30-2019 09:38 PM

My Kayak days are well and truely over but in our day we stashed so much gear in our Klepper Aerius IIs and went to sea looking for submarines all without skirts too.

Would you believe I i actually found a few videos on youtube.

I will have to send it to my mates to ensure they still remember how to assemble it!

have fun and I will keep following!

-- Regards Rob

View DustyMark's profile


447 posts in 2876 days

#2 posted 05-01-2019 06:00 AM

I’ve owned a pair of Nautiraid doubles when I was stationed with my family in Germany. I recently handed down a Long Haul Mark 2 to my daughter. Folding boats are super stable. I wish we could have kept the Long Haul, but my wife could not get comfortable in it when wearing their spray skirts. I’ll check out your video.

-- Mark, Minnesota

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