Building a Fishing Kayak Cooler #8: Installing the Ceiling and Feathering the Fiberglass Tape

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Blog entry by DustyMark posted 05-03-2019 06:00 PM 457 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 7: Fiberglassing a Panel and Taping the Outside Seams Part 8 of Building a Fishing Kayak Cooler series Part 9: Why Show a Fiberglass Intensive Project on a Woodworker's Site? »

Installing the Ceiling

I fiberglassed the ceiling before installing it since it’s a small area to work in.

The back side of the panel is glued in with foam adhesive. The front edge is epoxied to the wood cross frame piece. The panel is also held in by a bead of thickened epoxy. This maintains the waterproof integrity of the cooler. Using fiberglass tape was not needed for strength and would have been an incredible hassle to sand in this tight area.

The bead of epoxy is a bit rough in this photo. I applied a coat of thin epoxy to smooth it out a bit without resorting to sanding.

Feathering the Fiberglass Tape

The edges of the fiberglass tape swell up when soaked with epoxy. They need to be sanded to make a smooth transition from the wood to the tape.

Before sanding.

After sanding. It’s easy to remove too much fiberglass. Forming a short taper/feather is a better plan to leave more fiberglass over the surface of the joint.

Applying Second Fill Coat of Epoxy

After the tape was feathered, with an orbital sander, a second coat of epoxy was applied to seal the plywood and fill the weave of the tape.

It’s close to not needing a third coat of epoxy to fill the weave.

Each layer of epoxy is very thin since it’s squeegeed with a scraper. After the first coat soaks in, a little bit of epoxy goes a long ways on subsequent coats. It only took 3 ounces to complete the second coat.

Next Steps

1. Seal the top of the cooler.
2. Build the lid.

-- Mark, Minnesota

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