Re:Castable medium for boot floor.

Whatcha. I'm toying with the idea of reworking the back of Dreadnaught. Primarily making the plywood liner less creaky and also using the space better. Where I have got to is the idea of using some kind of castable resin or foam to anchor and support a thin impact layer that would otherwise not be strong enough to span the voids. I would like to be able to lift it out to clean and maintain. What I am struggling with is that while a resin would be strong and none porous but heavy and relatively expensive. Something like an expanding foam would be lighter and cheaper but would hold moisture and not be ultimately as strong as a solid resin? Is there some kind of material that is castable light weight none porous and reasonable in compression?

And noise deadner hmmm can't wait to hear what you come up with

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If you look at the expanded polystyrene blocks that stabilise and protect TV's etc whilst still in the packaging you will get an idea as to the loading ability. Also, they do not absorb water. I suggest you prepare a suitable plywood base that is bolted to the original seat bases, lay cling film to the original floor and underside of ply and then pump in foam from canisters available from builders merchants etc. The cling film will stop the foam from sticking to ply and floor. You may need to box in various items but that wont be difficult. Canal narrow boats use spray foam as an insulation throughout the interior so a word with a few builders may elicit suitable spray foam applicators. "Canal Boat" and " Narrow boat" are both mags that will give you a wealth of info on builders.

Roger

Can't think of anything that fits every need, you may need to go composite.
You could lay glass cloth or tissue (very thin woven fibre glass) over the boot area with a release agent, this makes the waterproof bottom layer. Then use expanding foam to fill the undulations, cutting flat once set. Then skin the top with thin plywood and finally glass cloth together. Finish with a paint or bed liner film of your choice. It's a technique (less the plywood) used in the Radio control world to make very strong but light foam cored composite wings. It's a lot of steps, but it would work.....
But will it fly

The practicality of the casting is simple enough once I have an idea of what to use. Will have more time with Google.

Just watched MythBusters Season 2 Episode 16 and in it they rebuild "Buster" the crash test dummy. They used a very tough silicon cast resin call Dragon Skin to manufacture body parts.
Your request came to mind, it looks possible to use it for a flexible and tough floor skin. Looks like you add a colourant of your choice, so no need for it to be pink!
Not investigated cost etc, but found a supplier in the UK.
www.benam.co.uk/products/silicone/addition/dragon-skin
Just throwing in as a possibility.
MIke

Cheers. Just looked through that and 2 problems, 5 gallons which might not be enough weighs 36 kg and costs 830 quid, both of which are prohibitive.

Currently I am looking into carving the shape out of kingspan and then sealing it up with glass fibre resin. This seems like the least messy option and the least hygroscopic as the top impact layer can be bonded on and sealed with the rest of the shape.

D'oh that is on the expensive side, but OK for a genuine Suzuki part 
yep composite was my original thinking, it's the combination that will make it light.
Hope you find something to do the job.
Mike

Would a 2 pack foam be any good?   Like this  

 

Interesting. Thanks