Ok here is the problem. I was given and old camp boat that was ripped to shit for a hurricane a few years back. I tore it down to the pontoons, They are made out of 24" pipe and about 30' long and have baffels five 5 feet. They are about 30 years old and have never been painted and are getting thin. I plan on blasting and painting it in the next few weeks. I was also thinking about filling them with some sort of flotation foam before I built on them again. I was told to mix a gallon or so at a time and just pour it in. The guy that sold the stuff said it is not that hard to do but he is the sales rep. I would really like to know how much of a pain in the a$$ it would be before i spend 1500 on the foam. Has anyone ever done this before?

Ask him for a 1 gallon demo and you be da judge of how hard it is by watchin him do it.

Foam pouring can get messy and you need to have everything setup right before you go about it. I was doing a small area in an old boat and had to calculate the cubic area and do some math before mixing I didn't want to much otherwise I'd have a volcano of mess on my hands

Back in high school I worked at a place that made life rafts that are on some boats offshore. Pretty easy to do but you need to make sure you are not using to much for the area you are trying to fill otherwise you will have a HUGE mess and wasted money.

To answer your question, no it's not hard. If a high school punk kid can work with this stuff then you should be able to handle it.

We had thin metaled pontoons once and used the mix to fill our 4 ft diameter pontoons. However, to use less liquid, we made some square cuts and put pieces of foam in first. Like Basin said, don't mix too much at a time and move quickly. It doesn't take long for the reaction to occur. Good luck.

filling them with foam will just make them heavier and prevent you from ever pumping them out.just my opinion

I would encase them in fiberglass and epoxy. Foam will and weight and u won't be ablle to purge leaks

x2 to what fasscoonass and dguidry said.....it will weigh u down quite a bit.