Springboard tunnel
After applying the epoxy filler coat I cut a hole in the front of the hull for the springboard. I made the hole bigger than it needed to be so I could fabricate a square fiberglass tube and bond it in.

To make the fiberglass tube I cut a piece of foam to the dimensions I wanted. I made the foam springboard 5.25" x 2.5". This is slightly larger than the finished size of the springboard. I wanted to leave a little room so I could wrap the final skin layers around and into the tunnel for a good hold. Once the foam springboard was the size I wanted I wrapped it in wax paper and glued it up with 3 layers of fiberglass and epoxy. After it hardened I was able to slide the foam out and was left with a rectangular fiberglass tube that could be slipped into the hole in the hull and bonded.



Here is the foam springboard I made so I could fabricate the rectangular tunnel.



Here is the fiberglass tunnel after it was bonded in with epoxy and high density filler. It was then trimmed with a dremel tool and the large voids were filled with Great Stuff polyurethane foam. Then it was sanded to the profile of the nose. The dark spot in the bottom of the tunnel is the hard point where two bolts will run through the springboard and out the bottom.



This is the back of the tunnel from the inside.



Filled and sanded.


Filled and sanded


Front