Rebuilding Sunpad/Engine Cover
 

So I'm getting ready to replace the sunpad/engine cover on my 97 Baja Islander 180 and need some advice. The wood is water-logged and rotten....foam is in perfect shape, and shop is making new vinyl for me (they're going to install the vinyl too).

So whatever I end up buying for plywood, I was thinking of coating with the West System epoxy resin. I have a few questions about this: I'll have to glue the foam back down to the wood....what adhesive should I use, and will it adhere to the epoxy resin? I should drill all holes before applying the resin, correct? Any other tips/advice would be awesome.

Thanks in advance, you guys.

west systems will work or standard resin. regular resin a lot cheaper......

Sweet, I'll check out some other epoxies. Anyone on the adhesive for the foam?

If you are going to seal the wood with resin you also need to use some type of glass to prevent the resin from flaking or cracking off. Now epoxy would hold without glass but under any kind of flexing it to would crumble over time.

Good point...I'm leaning more to epoxy as the old one was epoxied white and didn't crumble too bad for 17 years old (though it did crumble). I believe I have some white epoxy lying around, so that sounds like a plan. Thanks for the suggestions!

Do you have any thoughts on an adhesive to hold the foam down? 3M has a whole bunch of products..the 24 Fabric and Foam seems right, but the temp resistance is only 170-180F. I would think that since it's on the other side of the engine bay (which really shouldn't exceed 180F anyway, it should be fine. I'll do some more research, but any thoughts by anyone on the adhesive would be appreciated.

After putting the vinyl back on over the foam and stapling down, do you need to glue foam? I did my sunpad on the Formula and did not glue it down. It stays put, just a thought.

I didn't glue an old Fountain sunpad that I used to have. Always wondered if I should have.

Another note is that the factory wood was not sealed - thus it rotted. I used premium grade plywood from Lowe's, drilled holes, applied resin, and reinstalled - I'm sure it will last longer than the original wood did.

I'm trying to post some pictures for you guys....do I have to get a gold or platinum membership? The sunpad on this one curves down and forms the backrest for the rear bench, so they probably glued it so the foam would hold shape/contour while installing the vinyl.

any spray adhesive for holding foam down. it is when holding foam or vinyl UP that the glue matters.