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- 3 Sep 2024
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Hi. I have a kayak with a DIY storage area in the bow. Just added a trap door.
Inside I created a mold and filled it with light weight 2 lb. pour foam. I then pushed a flat cardboard box (the shape of a lithium battery) onto the foam to create a seat/shelf. The idea was to create a flat secure shelf for the battery.
It worked, except, well after it dried (and I removed the box), the foam continued to expand. This ruined the flatness of the shelf for the battery. The battery goes in but is not at all secure. It works but is ugly.
I'd like to shape the cutout in the now fully cured foam to a rectangle again. The floor of the foam that the battery sits on has bowed up and rounded. The access door is 10" wide by 7" tall. Also, I cannot remove the foam without grinding it to bits. So I have to work through the DIY access door.
So how can I work this lower surface of the foam to flatten it? Would a wood planer work?
I can see how to do the vertical sides using a hacksaw blade. I'm thinking the rear wall of the battery insert space would be flattened with a dremel since the rotary blade would be perpendicular to the floor.
Any thoughts?
Inside I created a mold and filled it with light weight 2 lb. pour foam. I then pushed a flat cardboard box (the shape of a lithium battery) onto the foam to create a seat/shelf. The idea was to create a flat secure shelf for the battery.
It worked, except, well after it dried (and I removed the box), the foam continued to expand. This ruined the flatness of the shelf for the battery. The battery goes in but is not at all secure. It works but is ugly.
I'd like to shape the cutout in the now fully cured foam to a rectangle again. The floor of the foam that the battery sits on has bowed up and rounded. The access door is 10" wide by 7" tall. Also, I cannot remove the foam without grinding it to bits. So I have to work through the DIY access door.
So how can I work this lower surface of the foam to flatten it? Would a wood planer work?
I can see how to do the vertical sides using a hacksaw blade. I'm thinking the rear wall of the battery insert space would be flattened with a dremel since the rotary blade would be perpendicular to the floor.
Any thoughts?