> Yeah, I know a guy localy who did something like that. The only real
> problem/ drawback is that the ouside of the boat is not even close to
> smooth. After around 5 layers of glass and poly on the top and seven on
> the bottom, (10-12oz glass and 5oz poly) it is really difficult to get
> even close to a smooth surface. You also miss out on the best parts of
> boatbuilding- spraying your own custom design with gelcoat, pigment and
> plenty of colors metal flake on the inside of a female mold and poping the
> boat from the mold is always exciting to.

Bart,

What I was really trying to get a at is a way to do a good one off - not a mould.

The idea with the foam forms is that you can sand into them a little bit and their density is similar to that of the surrounding spray foam. The idea of the colour change is that it is a good gauge of how close to the form you are sanding. The idea of the netting is that it is a gauge of how close to the shape you are getting. The idea of using foam is that it is quick to shape. It might be too rough though.

I don't really know if it would work, but this approach would go some of the way to reduce the use of multiple glass layers to achieve the shape. For weight reasons alone, this would be unacceptable. I'm thinking quick here.

-mike