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Old 01-04-2017, 12:28 AM   #2
lagfish
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Join Date: Aug 2016
Posts: 45
Re: Travel Float / Bag Stiffener Build

The core of the float will be made out of 2" thick 60PSI Expanded Polyurethane (XPS). XPS can be found at Home Depot or Lowes but up to 20-30psi. I've selected 60psi so that it will not crush down to 40m depth and will stand up to abuse. The outside will be covered with 1 or 2 layers 6oz fiberglass reinforced epoxy for water proofing and extra strength. The thin parts around the compartment and where the two pieces join will be reinforced with pine.

Here is all of the pieces purchased and cut to the right size. The XPS can be cut using a table saw but as I've learned you have to cut slowly or the foam will melt and stick to the blade and scream at you.



Here is the mock up of the float with all the pieces



and inside the bag



The float in bag configuration is exactly 62", which is the limit most airlines set before charging you extra.

Next step is the glue everything together and secure T-nuts to the one of the horizontal wood piece for joining in bag configuration.

Last edited by lagfish; 01-04-2017 at 12:38 AM.
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