Boston Whaler built its name on foam: the hulls are filled with it, and they float when swamped. That same construction is what a surveyor has to work around, because most of the hull can't be seen and water in the foam doesn't announce itself.
Water in the foam
Motor Boat and Yachting's review of the 305 Conquest tells buyers to make sure the foam between the hull skins is dry and hasn't taken on water through impact damage or poor repairs. Wet foam can't compress, so heavy pounding in a seaway will "hydraulic" the fibreglass, and the result is stress cracking on the inner hull. Its advice: have the hull checked for moisture by an experienced surveyor familiar with foam injected boats.
Where to look. Meter the hull and deck on a grid, comparing low areas with high ones. Look for stress cracks on the inner hull and deck, impact damage and repairs below the waterline, and fittings drilled through the skin that could let water into the foam. Ask how the boat was stored: on a trailer or in the water.
Glued grid liner with no access
Pascoe's review of the Outrage 26 found a grid liner and a lot of foam, with 2 inches of foam between the side liner and the hull. He compares the void spaces to "a house without an attic hatch" and questions both the strength of the glued parts and how well the glue holds. On the same boat, systems under the deck were hard to reach, batteries sat under a non latching hatch on the platform deck, and leaks had brought corrosion.
Where to look. Every hatch that opens: corrosion on wiring and terminals, battery security, and standing water.
Motor wells and cable openings
Pascoe's main concern on the Outrage 26 was the motor well: a large well with a big plastic hatch at the bottom and cable holes in its side below the level of the transom. At rest at sea, he writes, waves wash over the platform and water pours in through those openings, leaving a single small bilge pump to keep up. He also found oil tank caps that let water in if not screwed down tight.
Where to look. The height of every opening in the motor well against the waterline, the seals on hatches and cable boots, bilge pump capacity and float switch, and the oil tank caps.
Recalls
The USCG recall list holds four Boston Whaler records: the Conquest and Outrage, the 15 foot Dauntless, the 190 Outrage, and one covering various models. The detail pages don't give the defect. Give the hull number to a Boston Whaler dealer to find out whether a campaign applies and was done.
What to check on a Boston Whaler
| Area | What to look for | Source of the concern |
|---|---|---|
| Foam core | Moisture, impact damage, poor repairs | Motor Boat and Yachting, 305 Conquest |
| Inner hull | Stress cracks from wet foam | Motor Boat and Yachting, 305 Conquest |
| Grid liner | Glued joints you can reach, signs of movement | Pascoe, Outrage 26 |
| Motor well | Hatch and cable holes below the transom level | Pascoe, Outrage 26 |
| Under deck hatches | Battery security, corrosion from leaks | Pascoe, Outrage 26 |
| Bilge pump | Capacity and float switch | Pascoe, Outrage 26 |
| Recalls | Open campaigns for the hull number | USCG recall list |
Writing it up
"Hull, aft third below the cockpit sole: moisture readings well above those forward and above the waterline, with stress cracks on the inner hull at the aft bulkhead. Foam suspected wet. Recommend the extent is confirmed by a surveyor or repairer experienced with foam filled hulls before purchase." Record the readings on a sketch of the hull.