Re: making a rib
Part of the problem with expanding foam is that it is very difficult to get a consistant blow in the relatively restricted space. Theoretically not a big deal, but practically impossible. In addition, most of the foams you would use are not that structurally strong when cured unless they are molded under pressure. The cell structure will tend to deteriorate under the stresses applied. There are ribs with foam filled tubes, but they are molded in advance rather than just filled. I would be stoked to see someone pull this off, but I would hesitate to do this to a boat with value.