Building a Fishing Kayak Cooler #6: Making the Top

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Blog entry by DustyMark posted 05-02-2019 06:57 PM 407 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 5: Trimming the Cured Fiberglass Part 6 of Building a Fishing Kayak Cooler series Part 7: Fiberglassing a Panel and Taping the Outside Seams »

With the interior ready for another coat of resin, I fitted the top pieces.

The interior edges were traced directly onto the foam for a custom fit.

Nothing beats a track saw for cutting odd angles on projects like this. I use a sacrificial piece of foam for the blade to cut into. I often set this cutting operation up on my three folding shop tables. I’m using the tables at the moment, so I just worked on the floor.

1/2” of foam must be routed away around the hinge tabs. Tracing their outline in this photo.

Applying foam adhesive to bond the insulation to the interior ceiling piece.

High-tech foam clamps.

Second coat of epoxy resin applied to fill the weave of the interior fiberglass. Thickened epoxy applied to glue the top.

Seal coat of epoxy applied to the interior portion of the top. I’m not sure how much condensation will occur, so everything is coated, inside and out.

Top is screwed at the four corners to ensure alignment. Otherwise epoxy is holding the top on. Resist the urge to over tighten. Wood glue needs a lot of pressure; epoxy does not. Notice the scraper I used to squeegee the epoxy and the white vinegar I used to clean the uncured epoxy off my right arm after reaching into the cooler to remove glue squeeze out.

Next Step

The next step is to apply a layer of fiberglass to the ceiling piece and tape the outside seams of the cooler.

-- Mark, Minnesota

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