Can I use regular construction foam (PU spray foam) as a structural core for a boat?

Absolutely not. Hardware store spray foam is typically Open-Cell and low-density (0.5-1.5 lb/ft³). If the fiberglass skin cracks, water will wick through the entire hull structure in days (osmosis and rot). Marine-grade cores must be Closed-Cell with densities above 5 lb/ft³ (80 kg/m³) . Stick to PVC (Divinycell) or SAN (Corecell) specifically rated for marine use. Repairing a waterlogged hull core is a five-figure mistake.


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