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Offline Bob38

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Re: I will not be a victim of CRACK! (Update - Still Cracked....)
« Reply #60 on: July 21, 2019, 11:50:08 AM »
Chuck. Thanks for the info seems Tom has a great understanding of the problem and I will be posting some pics in the near future. I have to go through EVERYTHING on the Mokai when I get it. I don't want to set out in a faulty craft.

Offline Painlesstom

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Re: I will not be a victim of CRACK! (Update - Still Cracked....)
« Reply #61 on: July 21, 2019, 08:21:28 PM »
Just holler if you have any questions about anything. Nothing I can't help with.  \./8
Tom

  >:D    

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Offline waverunner

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Re: I will not be a victim of CRACK! (Update - Still Cracked....)
« Reply #62 on: July 31, 2019, 05:49:23 PM »
Tom,
New owner of a 2011 in very good shape and want to keep it that way. Do you feel that the spray foam is the best solution for filling in the voids to add rigidity inside the hull under the pump and around the intake tunnel? Or would it be better if I could create a temporary dam in those areas and fill with a flowable two part hardening resin that would create a cast for support. How well does the foam stick to the HDPE? Great site, Thanks

Offline Painlesstom

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Re: I will not be a victim of CRACK! (Update - Still Cracked....)
« Reply #63 on: July 31, 2019, 07:57:43 PM »
Welcome to the fun! Foam alone isn't enough, there needs to be something non compressible in the void under the pump to effectively transfer that motion and eliminate flex. I use two pieces of 1/4" HDPE stacked to make 1/2", then fill the rest with the spray foam making sure the underside of the tunnel is completely filled too. It takes a few days for the foam to fully cure and I use the Door and Window formula so it doesn't expand with so much force.  \./8
Tom

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Offline waverunner

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Re: I will not be a victim of CRACK! (Update - Still Cracked....)
« Reply #64 on: August 01, 2019, 05:58:02 PM »
I was curious how much that area under the pump moves so a couple of weeks ago I cut two blocks of wood to the thickness that made them very difficult to push in that gap between the bottom and the deck below the pump. The reason for doing this was to see if they would stay in place and then went for a ride on a smooth lake. Later when I looked they were both pushed out and were up around the engine, so there is a lot of flexing there. I can only imagine what goes on when I am bouncing the bottom off of rocks.

Offline Painlesstom

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Re: I will not be a victim of CRACK! (Update - Still Cracked....)
« Reply #65 on: August 01, 2019, 06:18:27 PM »
Exactly... It flexes enough to make the intake tunnel a hinge point.  >:(
Tom

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Offline waverunner

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Re: I will not be a victim of CRACK! (Update - Still Cracked....)
« Reply #66 on: May 09, 2020, 05:48:23 AM »
Decided to give my idea a try of using a hardening pourable epoxy to fill the voids under the pump and around the intake tunnel while extending far enough forward to get past the hinge point. So far I am pleased with the way it turned out and how well it is holding up.
I will report back after long term usage. I have ordered another drain plug to add to the other side.

Offline Painlesstom

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Re: I will not be a victim of CRACK! (Update - Still Cracked....)
« Reply #67 on: May 09, 2020, 08:05:12 AM »
I think you have the cleanest Mokai in existence!  :-O  That looks excellent, good job! I don't think you'll have any problem with that at all. Pretty impressive actually.  ;)
Tom

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Offline Hillbilly

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Re: I will not be a victim of CRACK! (Update - Still Cracked....)
« Reply #68 on: May 09, 2020, 09:25:05 AM »
Such a beautiful job, Waverunner.  How could you possibly get it so clean?  It looks "food grade".  Could you explain how you did it and materials used.  Thanks

Offline waverunner

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Re: I will not be a victim of CRACK! (Update - Still Cracked....)
« Reply #69 on: May 10, 2020, 06:16:09 AM »
Old yellow only looked that clean because I had just finished the pour and knew now was the time to take a pic. Last weekend she had all kinds of stream debris in her from tackling a very small stream near me that can not be attempted unless there is a very heavy rain which we got. I loved the look from people in their back yards who have probably never seen a kayak on this stream and which was going the wrong way, upstream.

First thing I did was prop up the bow and added water to determine what thickness epoxy I wanted in the back and where I wanted it to taper out on the floor towards the front. In the rear I wanted to slightly wrap up around the two corners of the pump floor to lock it in place from ever shifting side to side and I wanted it to end a couple inches in front of the hinge point. Drained and dried. Then I waxed everywhere I did not want any chance of the epoxy sticking even though the chances of it sticking well to the hull were slim. Foam insulation board was just the right thickness to have to compress under the pump floor and is easily shaped. I added a bead of clear caulk where needed on the foam to safeguard any leakage of epoxy during the pour. Do everything you can to safeguard against that as it would be a real mess. Also wax the edges of the foam to prevent the epoxy from sticking. The front dam is just flexible foam weatherstripping. The pour is done in 3 stages, bottom, 1/2 intake tunnel then other half. The epoxy I used was Epoxycast 650 with some yellow tint added only because I had some around. I did the first epoxy pour for the floor and let it dry then used spray foam to make a temporary plug that extended no more than 1/2 way through the intake tunnel.  Removed the plug and added some caulk and propped back in place. I turned the boat on its side and made the 2nd epoxy pour in the intake tunnel and let dry. Then I roughened up the epoxy with a die grinder and used drill bits to make some undercut holes in the surface so it will also have a mechanical bond to help prevent the two tunnel halves from ever separating. Then I poured the final half of the intake tunnel. I did change how the epoxy feathered out on the floor towards the front after it had dried. I originally had it feather to nothing but ended up cutting that off to reveal about a 3/16" step.

Offline Hillbilly

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Re: I will not be a victim of CRACK! (Update - Still Cracked....)
« Reply #70 on: May 10, 2020, 10:50:03 AM »
Great work.  Thanks for the story.

Offline CC-CODER

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Re: I will not be a victim of CRACK! (Update - Still Cracked....)
« Reply #71 on: May 10, 2020, 11:35:47 AM »
"I loved the look from people in their back yards who have probably never seen a kayak on this stream and which was going the wrong way, upstream." - waverunner

I too love the backyard waves and dumbfounded looks while heading up stream, especially from the Country Club golfers. I like carrying a golf ball with me for when they ask about the Mokai, then I ask...Is this your Ball? Lol

Nice job! Do you feel the need to add Tom's metal plate like he added to mine in the original post?
🤦🏼‍♂️ Chuck 🤷🏻‍♂️

Offline waverunner

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Re: I will not be a victim of CRACK! (Update - Still Cracked....)
« Reply #72 on: May 11, 2020, 04:46:09 AM »
I will eventually get around to adding some kind of plate as I feel Tom knows better than I do what these boats need to prevent future issues.

Offline Painlesstom

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Re: I will not be a victim of CRACK! (Update - Still Cracked....)
« Reply #73 on: May 11, 2020, 07:12:42 AM »
The plate is added insurance but alone didn't stop my boat from getting cracks. The inside support is key to this prevention and the plate is an extra layer of protection against leaks for ones that had cracks welded. Any boat I rebuild for sale gets the plate regardless. The two work together to strengthen the area, but from what I've seen so far a boat that has not cracked yet can get away with just supporting the inside. The one's I've supported the inside only haven't reported back with any problems yet.  \./8
Tom

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