I agree with Paul, I would not use mini-cell, too expensive, too hard to work, to flexible. The Dow insulation board is probably better. However, I think you would have better control over the shape if you strip-built the plug. You don't need to do a good job, just run enough strips to hold a layer of Bondo. Make cross-sectional forms, lay some strips over the forms, fair the strips slightly, cover with Bondo or joint compound, fair, fill hollows, fair, cover with fiberglass mat, fair, fill hollows, cover with a tooling gel-coat, fair, fill in hollows, fair, smooth, polish, buff.

The task is long and messy. It took me as long to make a plug as a complete stripper, and I was still a long way from getting a boat. strip-building the hull will probably save time over making a stack of topo-like layers because there will actually be less shaping/fairing/filling.

> Thanks for the rapid response! I think I will try the strip method also,
> but the C1 I envisioned and have sketched out is about 8 feet long and
> 29" wide at the cockpit. The design is more along the lines of a topo
> rather short and stubby. This would eliminate the long thin drooping ends
> ( I think).

> What about using the insulation board foam to build a plug. Cutting out
> the cockpit and then glassing it in. This would isolate the foam from
> water damage.

> Thanks again,

> Reuben Watkins