Preparing the Fiberglass
The plans provide templates for cutting the fiberglass to the correct size.
The edge is trued by flattening the cloth on the table and pulling out strands one at a time to even the edge. The circular cutter is used to trim it true.
The patterns are used to cut the cloth panels to size.
The First Coat
The first coat of epoxy is applied with a disposable chip brush and a 4″ foam roller. It is important that every piece of wood is well coated to protect the wood.
The bottom of the boat will be reinforced with 6 ounce fiberglass cloth. The fiberglass is best applied before the first coat is cured for best chemical adhesion.
In order to achieve both a chemical and mechanical bond, the subsequent application should be done over the first while it has just barely hardened. If the brands are not from the same manufacturer there is a possibility of curing issues.
I began making the fillets from Magic Gel, an epoxy product that comes with a thickener ready to apply. I am using MarinEpoxy here to lay the fiberglass, so I had to let the fillets harden and sand them before the next layer. I quickly switched over to the wood flour and epoxy mix to avoid a lot of nasty sanding.
Now the entire bottom has at least one coat and the fiberglass is being applied.
After the floor was laid in and fillets completed, it was coated with 3 coats of epoxy.
The transom knee was added and the fillets are being sanded down before the final coat.
This a major milestone. All of the necessary work is done on the interior under the deck and the boat is ready to flip over for the bottom work.
On the bottom side now. The frame tabs needed to be trimmed, there were seams and stitch holes that needed to be faired. Some trimming, and there always needs to be a little bit of sawdust made.
A block of Spanish Cedar was trimmed to a triangle with my favorite saw. Glued and screwed into place until the glue dries, it gets shaped in to the nose block.
After a first coat of epoxy the 6 ounce fiberglass is laid out and smoothed out. Epoxy was poured on and smoothed out with a scraper and a roller. The excess was worked down to the sides and finished out.
I raised the transom up and the nose down and hung it from the garage door opener.
The cloth was placed and finished out with about 4 coats. All of the exposed wood is now sealed.