Plywoood Parts
Sides and Bottom constructed from 3/8" Thick BS 1088 Okoume Marine Plywood.
CNC Router cut the parts to size from 4' X 8' Sheets
Puzzle joints utilized on Sides and Bottom where OAL exceeded 8'.
Keeping OAL under 8' avoided prohibitively costly truck shipment.
Sides - Bow Sections
(3) Side Bow Sections fit in a 4 X 8 Sheet. (2) Sheets Reqd.
Sections shipped within the 4 X 8 sheet to avoid shipping damage.
Sides - Stern Sections
(3) Side Stern Sections per Sheet. (2) Sheets Reqd.
Bottom - Stern Section
(1) Bottom Stern Section per Sheet. 3 Sheets Reqd.
Bottom - Bow Sections
(3) Bottom Bow Sections per Sheet - 1 Sheet Reqd.
Bottom Glass
Fiberglass layed-out on the Bottom ready for wet-out.
Interior Fiberglass was applied in advance of Assembly to the plywood parts.
This simplified the application of Fiberglass to the Interior which would have been complex in an assembled boat due to corners.
A Fixture was contructed to support the parts during the Glasswork.
Weights were hung under the parts to achieve pre-bend and match their finshed shape on the boat.
Bottom Glass Wet-out
Fiberglass cloth was wet-out with epoxy and
(3) additional coats were brushed over after a 12 hour green cure.
Note the Centerlines placed on both sides of the bottom to facilitate accurate assembly.
Bottom Prep Complete - Stern Section
After a 72 hour cure, the resin was sanded and a string and stick used to maintain the pre-bend so the bottom could be removed from the fixture.
Bottom Bow Section Layed-up in Glass
Fiberglass cloth layed-up and wet out with epoxy.
Bow Side Sections
Bow Side Sections scribed to show locations of Chines & Ribs on interior, Gunwales on exterior.
Top inside edge routed with 1/4" radius bit to achieve rounded edge for glass.
Stern Side Sections
Stern Side Sections scribed to show locations of Chines, Ribs & Dedication Panels on interior, Gunwales on exterior.
Dry-fit Assembly
Boat Dryfit with Stem, Sides, Center Brace, and Transom to confirm accuracy.
Pre-bend
Automotive battery used to provide the weight for the pre-bend on the fixture.
Glass Lay-upn
Sides layed-up in fiberglass cloth.
Ready for Epoxy Wet-out.
Epoxy Wet-out
Sides wet-out with epoxy.
Dedication panel printed on Rice paper and wet-out underneath glass cloth.
Weights
Another View of the Weights under the Sides & Fixture.
Weights
Close view of the weight.
Rib Installation
Ribs and sides were pre-drilled to be fastened with flathead screws.
Sides were counter-sunk to achieve screws flush with outer face.
Ribs were embedded in thickened epoxy.
Fillets were troweled on both sides of the Ribs.
Rib View
Rib Fillet
Rib Fillet Tool
Sanding
Sides were sanded and string and sticks added to retain pre-bend when removed from fixture.
Ribs still curing, but will also be sanded after 72 hour cure.
Dedication Panels
Dedication Panels were taped off and (8) coats of varnish applied to protect epoxy from destructive UV radiation.
Balance of boat will be painted to protect it.