Stem / Side Assembly
Port and Starboard Sides attached to Stem with Screws and thickened Epoxy.
String and Sticks maintained pre-bend in sides until Center Frame and Transom were attached.
Interior glass-work was done previously and the pre-bend was maintained to insure glass and epoxy was not subjected stresses which might lead to delamination.
Bottom Assembly
Bow and Stern bottom sections attached with Puzzle Joints and Titebond 3 glue.
Batteries serve as weights to keep joint tight during cure.
Center Frame Installation
Center Frame embedded in thickened epoxy, clamped, and screwed to sides.
Note wedges(held in place with C-Clamps) to allow use of large clamp during cure.
Center Frame
Clamps must remain in place during epoxy 72 hour cure time.
Transom Installation
Transom clamped, joints filled with thickened epoxy, and screwed in place.
Basic Form Complete
The attachement of the Stem, Center Frame, and Transom to the sides creates the basic form of the boat.
Bottom Assembly
Bottom Puzzle Joint sanded and prepared for glass.
Interior of both Bottom Bow and Stern Sections were previously layed-up in glass & epoxy.
Chine Installation
Chines installed, joints filled with thickened epoxy, and clamped in place.
3/8" Fillet (Thickened Epoxy) applied between Chine and Sides.
Cure time 72 Hours.
Chines required compound angles at both bow and stern to fit.
Each Chine was composed from (2) pieces with a common finger joint to join them (See Gunwale Construction page for reference).
Puzzle Joint Layed-up in Glass
Fiberglass Sheet layed-up on Puzzle Joint and wet-out with epoxy.
Clamped-in-place Chines curing on Hull in background.
Router Jig
Router Jig for milling Chines Flat & Parallel to accept Bottom.
Jig establishes theoretical surface parallel with bottom.
Router Jig
Door Hinges, attached to bottom of Jig, allow it to be clamped to the Sides of the Boat
The Hinges pivot slightly, as the Jig is moved along the sides, to accommodate the changing angle.
Routing Complete
Chine bottom surfaces routed flat and parallel.
Ready for Bottom Installation.
Thickened epxoy to applied on this surface for bottom attachement after fitting.
Bottom Layout
Bottom fit to boat and sides traced.
Epoxy now applied inside of tracing on Bottom
Bottom Installation
Bottom set in place. Batteries serve as weights.
Brad nails used to attach Bottom to Chines.
3/8" Fillet (Thickened Epoxy) applied between Chine and Bottom.
Bottom Cure
Again, 72 hour cure for epoxy.
Finish & Prep
Excess bottom material remove with Saber Saw
Edge rounded with 3/8" radius Routing Bit and bearing.
Ready For Glass
Plywood surface and excess epoxy is sanded with #80 grit in preparation for fiberglass lay-up.