TotalBoat 2.72 kg Density Expanding Polyurethane Boat Foam — 7.57 L Kit, High-Compression 94% Closed-Cell Flotation & Structural Fill

TotalBoat 6 lb density two-part expanding polyurethane foam is a fast-curing, rigid marine-grade foam designed for flotation, structural fills, casting and carving.

This two-gallon kit delivers a high-compression, 94% closed-cell foam that expands rapidly after a simple 1:1 mix. It’s formulated for boatbuilders and makers who need a durable, paintable substrate that bonds well with epoxy, polyester and vinyl ester systems. The foam is made in the USA and works equally well for hull flotation, core fills, moulds, props and sculptural pieces when mixed and applied under the right conditions.

How quickly does the foam cure and how do I mix it correctly?

The TotalBoat 2-part foam sets up fast at room temperature and requires a straightforward 1:1 resin-to-activator ratio. Stir vigorously for about 25 seconds, pour immediately and allow the foam to expand and harden undisturbed for a full cure.

• Mix ratio: 1 part resin : 1 part activator by volume.
• Stir time: ~25 seconds of vigorous mixing.
• Ideal working temperature: 75–85°F for proper expansion.
• Pour method: pour immediately after mixing; use multiple thin pours for large cavities.

What can I use this foam for on and off the water?

This high-density formula is versatile—use it for buoyancy blocks, structural reinforcement, mould plugs, stage props, carving and many fabrication tasks. Once cured it machines, sands and paints cleanly, and will accept most common marine resins and coatings for final finishing.

• Flotation: foam supports hull buoyancy and fills voids.
• Structural fills: reinforces stringers, floors and bulkheads.
• Casting and sculpting: ideal for plugs, signs and props.
• Compatibility: bonds with epoxy, polyester and vinyl ester coatings.

What performance should I expect—strength, density and water resistance?

The foam cures to a rigid, 6 lb/ft³ density with high compressive strength and predominantly closed cells that resist liquid penetration. Minimal shrinkage on cure and good mechanical bonding between pours make it reliable for load-bearing fills and flotation.

• Density: 6 pounds per cubic foot (high-density formula).
• Cell structure: ~94% closed cells for reduced water absorption.
• Yield: 2-gallon kit yields roughly 3 cubic feet of cured foam.
• Flotation: mixed two-gallon kit provides about 92 lbs of buoyant support.

What precautions and working tips improve results?

Temperature control, accurate measuring and adequate ventilation are critical for consistent expansion and safe handling. Warm, steady conditions and layered pours for large volumes will produce stronger, more uniform fills.

• Temperature: maintain 75–85°F for best expansion and cure.
• Venting: allow room for expansion—foam can expand dramatically.
• Personal protection: use gloves, eye protection and ventilation when mixing/pouring.
• Layering: pour in stages for large cavities to maximize bonding and strength.

Who this product is for: TotalBoat 6 lb density expanding polyurethane foam suits boatbuilders, marine repair technicians, model makers, prop fabricators and DIYers who need a high-strength, paintable closed-cell foam for flotation, structural fills or creative casting. If you require a fast-curing, machineable foam that integrates with common marine substrates and resins, this two-gallon kit offers upfront convenience and reliable performance when used under recommended conditions.