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 Excel foam removal 
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Joined: Thu Oct 30, 2014 8:25 am
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Post Excel foam removal
Picked up a 2013 1854 f4 excel knowing all the issues with boat/motor. Thought I would share pics to help the next guy

Sanded paint at the areas I would be welding. Took a 5/8 hole saw and drilled all the plug welds. You can see the PO installed pedestal mounts. They didn’t screw into the rib so I’ve time a lot of the plug welds ripped


I used a jigsaw for the most part and an angle grinder for going across the ribs.




Cut holes in the pods as well and found they have a formed channel. I went 4” and 16” off the transom gussets. The channel stops right around 16” so save yourself the headache I had and cut @17”. I couldn’t get my jigsaw or grinder any closer to the boat so I had to make an addition cut and bent the channel out of the way.



The foam is a pain in the ass to remove. I used a sawzall with a long dong blade to “grid” cut. Once I got what I could by hand, I used a pressure washer to get the rest out.
One of the plugs goes to the battery/bilge area. The other is for the pods. There’s a rectangular tube behind the bilge that connects the pods to the rest of the boat. It looks like they duct taped the pod side but then foamed everything so that drain plug did nothing. The passenger side pod is not connected to the drivers side so I need to add another plug otherwise i will always have 3” of water in it if I were ever to get water in it.

Not sure the reason why they have bracing how they do. The passenger side doesn’t have good drainage at all. The bottom of these boats are spliced down the center with about a 1-1 1/2” flange so there no way for the water to get to the other side besides maybe in the very back. The boat does drain fully, but noticed the passenger side takes longer.






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Sat May 11, 2019 4:30 pm
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Joined: Thu Jul 20, 2017 6:23 am
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Post Re: Excel foam removal
Looks very well done. A lot of work went into that.


Mon May 13, 2019 3:20 am
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Joined: Sat Sep 30, 2017 7:10 pm
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Post Re: Excel foam removal
Yeah for sure, that looks professional


Mon May 13, 2019 6:31 pm
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Joined: Mon Aug 29, 2016 12:39 am
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Post Re: Excel foam removal
Thanks for sharing.


Sat May 18, 2019 8:10 pm
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Joined: Wed Sep 16, 2015 11:50 am
Posts: 284
Post Re: Excel foam removal
that is a tremendous effort! boat looks great! whats the game plan now? you going to turf the floor and top of the pods?


Mon May 20, 2019 10:16 am
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Joined: Mon Jul 31, 2017 8:02 am
Posts: 6
Location: Arkansas
Post Re: Excel foam removal
I have the exact same boat. What would you estimate the weight difference is now and was the foam saturated? I know after a morning of getting in and out of the boat hunting it usually takes 2-3 days before it finishes dripping water out.

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2016 Excel F4 1754 w/ GTR 37 EFI on Diamond City Trailer


Mon Jun 03, 2019 9:52 am
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Joined: Thu Oct 30, 2014 8:25 am
Posts: 15
Post Re: Excel foam removal
I never weighed the boat or foam. I have heard claims of 300-600#. The boat sits over 2” higher at the pods now. I put a stage 1 kit on my 35 hd sport so I couldn’t tell you the gains either. I can get 28.5 with 2 guys and 2 dogs.

Eventually I will hydroturf it


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Sun Jun 09, 2019 8:33 pm
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Post Re: Excel foam removal
That’s good numbers bro


Sun Jun 09, 2019 9:15 pm
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Joined: Fri Jan 10, 2014 1:16 pm
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Post Re: Excel foam removal
That was a man size job, nice work sir


Sun Jun 09, 2019 10:59 pm
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Joined: Wed Dec 08, 2010 3:48 pm
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Location: Sallisaw , Oklahoma
Post Re: Excel foam removal
GonNa tackle this exact project this summer! Thanks for the tips!


Wed Dec 30, 2020 1:38 pm
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Joined: Tue Jul 31, 2018 7:55 pm
Posts: 36
Post Re: Excel foam removal
Do the newer boats from excel have this same problem?


Sat May 22, 2021 4:25 pm
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