The largest error we've made in working on boat projects is beginning without having the needed materials

I expected to miss stuff. Boat builders have a parts dept. When they need something they walk 100' and pick it up. Working on a project boat in the back yard or at a boat yard we found searching for parts, tools, and components ate up a great deal of time. The better organized one is, the less time the project will take. We ended up traveling to buy a tubing benders; twice. because the first set of "cheap" ones wouldn't actually fit the tubing. I returned it to Harbor Freight, no problems. I showed them how it didn't work. We received our money and watched as the manager put it back on the sales floor shelf. Amazing! I then drove to a refrigeration supply and bought a high quality bender. Had we done that the first time I would have saved a day's travel and still paid the same price.

First we cut and laid out the blue board without any foam. I numbered the pieces so I would know how they all went together. Once I knew what went where I could fill in the voids. The curvature of the hull offered the largest void problem area. After we painted all the raw glass placed two layers of the Space Insulation from FourWinds. (ps-Glacierbay evaluation of the material wasn't too glowing). According to the R - value it is not the best. What is good about it was the UV material. The Aluminum coating on two fronts and one back. Fiberglass boat hulls are translucent and I didn't want UV warming our boxes up. The boxes will take enough energy anyway. After lining the hull with the Space Insulation and then I made a 1/2 plywood board. Drilled 15 or so 1 1/2" holes in it and lined it with visqueen. I marked on the side with a straight piece of blueboard and I tacked it in place. Next I poured expanding foam into the holes. I did about 6 or 7 pours. Expanding foam can exert a lot of pressure I did not want to break anything. This too eliminated hollows created by too much foam. Once poured and cured I removed the plywood and had a flat surface to lay the blueboard against.

I now had the outboard side ready I began layering the blueboard. I over lapped all the edges and used spray foam to seal any gaps.

When I ended up near where the liners would go I stopped and began the fitting. Now I needed some patterns for the Vacuum Panels. (VPs). I taped 3/4" blueboard and 1/4" blueboard Itogeather together. The patterns allowed a perfect fit for each panel. ( In my rebuild 15 years later I discuss the issue with VP's.

While we waited for the VP's I began working on the plate install in the liners. The coldplates were placed as high in the boxes as possible. I marked where the attachment holes were and drilled the liners. I then attached two pieces of 1/2" ply to the outside of the boxes. The cold plates were then attached using wellnuts. With the plates in the next step was to plumb it all together.

In 2020-2021 we ripped out the system and put in 3 Engels. While what we had worked like a champ there were problems, mostly that it didn't perform as expected.

I've created a pictoral history of the various stages of the works: General Installlation, Insulation, Layout, and Liners.