Syntactic foam base

Frankie Pellegrino · 5th January 2007, 22:31

Dear Boris Comrades
This is my syntactic foam base. The three reasons I made this are.
1)Rises the kit up 3 ½ inches for ease of donning (makes a big difference on a rocking boat)
2) Give the ass end some needed buoyancy (Trim like a perfect under water glider

)
3)And to mount a small Dry suit / BC inflation bottle and an extra small O2 Bottle to my on board tanks.

To make one you have to purchase the foam in a block and cut and shape it your self. Then just sand it smooth and paint it your favorite color. You can use a handsaw or band saw or even a skill saw they all work. It’s a very easy material to work with. But it’s very expensive. A 12inch by 12inch by 3inches thick piece can cost $150.00 dollars. Make sure you buy ocean grade foam if you dive deep. Other wise it will crush at depth. To purchase some just do a google search for “syntactic foam” a bunch of companies will pop up. The black bottom is actually a cutting board you can buy at your local home goods store. I can’t believe I found a black cutting board but I did. I originally had a piece of plywood. It worked well but the cutting board makes it look so much better. You also have to buy longer stainless steel bolts to secure it to your kit. I counter sunk the bolts so they wouldn’t rub. I’m sure you’ll enjoy my pictures.

The foam in a raw state. I had this left over after making it

back view standing on it's own

side view

view of the cut out showing that you can get to your isolation valves

The REAL back view

(Notice that you can still get to the side mount brackets)

I just didn't think it was right to show the back view with out seeing the front view. She only likes to play & splash with Boris guys

It really works awesome! Cheers Frankie

dive2dive2000 · 5th January 2007, 22:52

I think its time I start diving a Boris

Nice Job, nice pics, very innovative... Have some green

narked at 90 · 5th January 2007, 23:56

Hi, and well done, have you found any problems at depth? as in the compression of the foam and loss of trim? i know you say buy the ocean ratted foam but is it good at depth?????
and Isn't that the same as Kevin's foam bottom thats in the works??
kind regards john routley

**rdriver** · 5th January 2007, 23:59

I'm very familiar with this foam, I used a ton of it making Glasair I RG they refer to it as high density foam you use two layers of Bid (BI directional) Fiberglass cloth over it with vinyl ester resin and it makes it incredibly strong..... anyway nice job...and great looking dive partner too.....
Dive Safely
Rob

narked at 90 · 6th January 2007, 00:13

by the way.... very nice Tea pots

Frankie Pellegrino · 6th January 2007, 01:21

Quote: (Originally Posted by narked at 90)

Hi, and well done, have you found any problems at depth? as in the compression of the foam and loss of trim? i know you say buy the ocean ratted foam but is it good at depth?????
and Isn't that the same as Kevin's foam bottom thats in the works??
kind regards john routley

Hey John
I was told it was rated to full ocean depth. I really don't know what that means, I'm sure you can go very very deep before it crushes. I did a 370 foot dive with some other foam I had, and it CRUSHED! My friend which was right next to me used this foam and it looked perfect after our dive. I'm sure this wouldn't crush to any depths that I or you would go to. After that dive I purchase a block of syntactic foam.

When that foam crushed my trim wasn't to good. My kit got ass heavy. So the syntactic foam is the perfect solution.

I'm not sure but I believe this is the same stuff Kevin is working with. It's so expensive, so for his company to put a finished product out. Lets say fiber carbon cover or fiber glass cover to match our Boris. It would be super expensive to sell a finished product. But that's only a guess!
Cheers Frankie

narked at 90 · 6th January 2007, 01:38

Hi franky, full ocean deapth..thats scary! i guess that why it cost so much!
we can wait for Kevin for a long time to come before these little problems are put right....(SORRY KEV)

the little stand i made was a one off made to general specks but for what we could do with out getting a lawsuit using the Ali made very little difference to the trim as the in water weight was just about nothing.
could you sculpt a hole through you foam that would take a tank?
kindest regards john routley

Quote: (Originally Posted by Frankie Pellegrino)

Hey John
I was told it was rated to full ocean depth. I really don't know what that means, I'm sure you can go very very deep before it crushes. I did a 370 foot dive with some other foam I had, and it CRUSHED! My friend which was right next to me used this foam and it looked perfect after our dive. I'm sure this wouldn't crush to any depths that I or you would go to. After that dive I purchase a block of syntactic foam.

When that foam crushed my trim wasn't to good. My kit got ass heavy. So the syntactic foam is the perfect solution.

I'm not sure but I believe this is the same stuff Kevin is working with. It's so expensive, so for his company to put a finished product out. Lets say fiber carbon cover or fiber glass cover to match our Boris. It would be super expensive to sell a finished product. But that's only a guess!
Cheers Frankie

Frankie Pellegrino · 6th January 2007, 02:02

.
could you sculpt a hole through you foam that would take a tank?
kindest regards john routley[/quote]

John
The stuff is very easy to work with. And you could easily sculpt a hole through it. I just think that you would cut to much of the material out if you wanted to make space for a tank. You would take away that needed buoyancy. If you were to do that then you would have to fiberglass cover it. Just my opinion.

Cheers Frankie

DrJM · 6th January 2007, 08:38

Quote: (Originally Posted by narked at 90)

Isn't that the same as Kevin's foam bottom thats in the works??kind regards john routley

No offense to Kev but view from behind (or the front) it's defintely not the same shape

Sorry that was too easy

***Decodiver*** · 6th January 2007, 10:08

Nice work Frankie.....you devil!

I am due to get the first CCRB prototype foam stand when it rolls out this month (hopefully).

I will let you know how I get on with it & post some pics when it arrives.

They have the foam, like Frankie's and have a new piece of equipment to machine it, so I am really looking forward to the result.

I have waited along time but am sure it will be what I need to be able to put 3 litre stumpies onto my Boris.

I also need to do a review of the Golem radial scrubber & the nice reel I got from Kent Tooling.

Cheers,

Dave Cooper.

5th January 2007, 22:31	#1 (permalink)
Frankie Pellegrino Custom Title Allowed! Current Rebreather/s: Classic Kiss Ouroboros Other Rebreather/s: Inspiration Classic Join Date: Jan 2006 Location: NYC New York Posts: 134	Syntactic foam base Dear Boris Comrades This is my syntactic foam base. The three reasons I made this are. 1)Rises the kit up 3 ½ inches for ease of donning (makes a big difference on a rocking boat) 2) Give the ass end some needed buoyancy (Trim like a perfect under water glider ) 3)And to mount a small Dry suit / BC inflation bottle and an extra small O2 Bottle to my on board tanks. To make one you have to purchase the foam in a block and cut and shape it your self. Then just sand it smooth and paint it your favorite color. You can use a handsaw or band saw or even a skill saw they all work. It’s a very easy material to work with. But it’s very expensive. A 12inch by 12inch by 3inches thick piece can cost $150.00 dollars. Make sure you buy ocean grade foam if you dive deep. Other wise it will crush at depth. To purchase some just do a google search for “syntactic foam” a bunch of companies will pop up. The black bottom is actually a cutting board you can buy at your local home goods store. I can’t believe I found a black cutting board but I did. I originally had a piece of plywood. It worked well but the cutting board makes it look so much better. You also have to buy longer stainless steel bolts to secure it to your kit. I counter sunk the bolts so they wouldn’t rub. I’m sure you’ll enjoy my pictures. The foam in a raw state. I had this left over after making it back view standing on it's own side view view of the cut out showing that you can get to your isolation valves The REAL back view (Notice that you can still get to the side mount brackets) I just didn't think it was right to show the back view with out seeing the front view. She only likes to play & splash with Boris guys It really works awesome! Cheers Frankie
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5th January 2007, 22:52	#2 (permalink)
dive2dive2000 PRISM DIVER & LUVIN IT! Current Rebreather/s: Prism Topaz Other Rebreather/s: Join Date: Feb 2005 Location: Long Island, NY Posts: 776	Re: Syntactic foam base I think its time I start diving a Boris Nice Job, nice pics, very innovative... Have some green __________________ Safe Diving, Martin "but what's the fun of getting what you need, instead of what you want?"
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5th January 2007, 23:56	#3 (permalink)
narked at 90 In my own little world Current Rebreather/s: Inspiration Classic Other CCR Dolphin Home Build Other Rebreather/s: Not Bought Yet Inspiration Classic Classic Kiss Other CCR Dolphin Home Build Join Date: Feb 2005 Location: middlands uk Posts: 992	Re: Syntactic foam base Hi, and well done, have you found any problems at depth? as in the compression of the foam and loss of trim? i know you say buy the ocean ratted foam but is it good at depth????? and Isn't that the same as Kevin's foam bottom thats in the works?? kind regards john routley __________________ CHECK OUT OUR INTERWEBS FOR CUSTOM REBREATHER UPGRADES *WWW.NARKEDAT90.CO.UK* *WWW.GRPSERVICES.COM* Last edited by narked at 90 : 6th January 2007 at 00:01.
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5th January 2007, 23:59	#4 (permalink)
rdriver Supporting Member Current Rebreather/s: Megalodon Other Rebreather/s: Sport Kiss Classic Kiss Join Date: May 2005 Location: Monroe, WI 53566 U.S. Posts: 148	Re: Syntactic foam base I'm very familiar with this foam, I used a ton of it making Glasair I RG they refer to it as high density foam you use two layers of Bid (BI directional) Fiberglass cloth over it with vinyl ester resin and it makes it incredibly strong..... anyway nice job...and great looking dive partner too..... Dive Safely Rob
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6th January 2007, 00:13	#5 (permalink)
narked at 90 In my own little world Current Rebreather/s: Inspiration Classic Other CCR Dolphin Home Build Other Rebreather/s: Not Bought Yet Inspiration Classic Classic Kiss Other CCR Dolphin Home Build Join Date: Feb 2005 Location: middlands uk Posts: 992	Re: Syntactic foam base by the way.... very nice Tea pots __________________ CHECK OUT OUR INTERWEBS FOR CUSTOM REBREATHER UPGRADES *WWW.NARKEDAT90.CO.UK* *WWW.GRPSERVICES.COM*
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6th January 2007, 01:21	#6 (permalink)
Frankie Pellegrino Custom Title Allowed! Current Rebreather/s: Classic Kiss Ouroboros Other Rebreather/s: Inspiration Classic Join Date: Jan 2006 Location: NYC New York Posts: 134	Re: Syntactic foam base Quote: (Originally Posted by narked at 90) Hi, and well done, have you found any problems at depth? as in the compression of the foam and loss of trim? i know you say buy the ocean ratted foam but is it good at depth????? and Isn't that the same as Kevin's foam bottom thats in the works?? kind regards john routley Hey John I was told it was rated to full ocean depth. I really don't know what that means, I'm sure you can go very very deep before it crushes. I did a 370 foot dive with some other foam I had, and it CRUSHED! My friend which was right next to me used this foam and it looked perfect after our dive. I'm sure this wouldn't crush to any depths that I or you would go to. After that dive I purchase a block of syntactic foam. When that foam crushed my trim wasn't to good. My kit got ass heavy. So the syntactic foam is the perfect solution. I'm not sure but I believe this is the same stuff Kevin is working with. It's so expensive, so for his company to put a finished product out. Lets say fiber carbon cover or fiber glass cover to match our Boris. It would be super expensive to sell a finished product. But that's only a guess! Cheers Frankie
(Offline)

6th January 2007, 01:38	#7 (permalink)
narked at 90 In my own little world Current Rebreather/s: Inspiration Classic Other CCR Dolphin Home Build Other Rebreather/s: Not Bought Yet Inspiration Classic Classic Kiss Other CCR Dolphin Home Build Join Date: Feb 2005 Location: middlands uk Posts: 992	Re: Syntactic foam base Hi franky, full ocean deapth..thats scary! i guess that why it cost so much! we can wait for Kevin for a long time to come before these little problems are put right....(SORRY KEV) the little stand i made was a one off made to general specks but for what we could do with out getting a lawsuit using the Ali made very little difference to the trim as the in water weight was just about nothing. could you sculpt a hole through you foam that would take a tank? kindest regards john routley Quote: (Originally Posted by Frankie Pellegrino) Hey John I was told it was rated to full ocean depth. I really don't know what that means, I'm sure you can go very very deep before it crushes. I did a 370 foot dive with some other foam I had, and it CRUSHED! My friend which was right next to me used this foam and it looked perfect after our dive. I'm sure this wouldn't crush to any depths that I or you would go to. After that dive I purchase a block of syntactic foam. When that foam crushed my trim wasn't to good. My kit got ass heavy. So the syntactic foam is the perfect solution. I'm not sure but I believe this is the same stuff Kevin is working with. It's so expensive, so for his company to put a finished product out. Lets say fiber carbon cover or fiber glass cover to match our Boris. It would be super expensive to sell a finished product. But that's only a guess! Cheers Frankie __________________ CHECK OUT OUR INTERWEBS FOR CUSTOM REBREATHER UPGRADES *WWW.NARKEDAT90.CO.UK* *WWW.GRPSERVICES.COM*
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6th January 2007, 02:02	#8 (permalink)
Frankie Pellegrino Custom Title Allowed! Current Rebreather/s: Classic Kiss Ouroboros Other Rebreather/s: Inspiration Classic Join Date: Jan 2006 Location: NYC New York Posts: 134	Re: Syntactic foam base . could you sculpt a hole through you foam that would take a tank? kindest regards john routley[/quote] John The stuff is very easy to work with. And you could easily sculpt a hole through it. I just think that you would cut to much of the material out if you wanted to make space for a tank. You would take away that needed buoyancy. If you were to do that then you would have to fiberglass cover it. Just my opinion. Cheers Frankie
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6th January 2007, 08:38	#9 (permalink)
DrJM Deep Cave Explorer Current Rebreather/s: Ouroboros Other Rebreather/s: MK 15.X Join Date: May 2005 Location: France Posts: 335	Re: Syntactic foam base Quote: (Originally Posted by narked at 90) Isn't that the same as Kevin's foam bottom thats in the works??kind regards john routley No offense to Kev but view from behind (or the front) it's defintely not the same shape Sorry that was too easy __________________ www.snoopyloop.com Deep Cave Exploration Last edited by DrJM : 6th January 2007 at 08:46.
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6th January 2007, 10:08	#10 (permalink)
*Decodiver* Administrator Current Rebreather/s: Megalodon Ouroboros rEvo Other CCR Other Rebreather/s: Inspiration Classic Inspiration Vision Evolution Sport Kiss Classic Kiss rEvo Other CCR Join Date: Jan 2005 Location: Geneva Posts: 2,164	Re: Syntactic foam base Nice work Frankie.....you devil! I am due to get the first CCRB prototype foam stand when it rolls out this month (hopefully). I will let you know how I get on with it & post some pics when it arrives. They have the foam, like Frankie's and have a new piece of equipment to machine it, so I am really looking forward to the result. I have waited along time but am sure it will be what I need to be able to put 3 litre stumpies onto my Boris. I also need to do a review of the Golem radial scrubber & the nice reel I got from Kent Tooling. Cheers, Dave Cooper. __________________ CCR/OC Trimix Instructor Trainer CCR Training to Mixed Gas in Switzerland, France, UK & Germany on Megalodon/COPIS-Megalodon/KISS/Sport KISS/Ouroboros/rEvo/Inspiration/Evolution/Sentinel www.zerogravitydiving.com Rebreather World Terms & Conditions Last edited by Decodiver : 6th January 2007 at 22:19.
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