Flats boat PROJECT....Updated w/pics!

[maxum247]

Re: Flats boat PROJECT....Updated w/pics!

The plywood strips should work fine but if you can make them a little wider so the glue get's as good a bite as possible. You'll want a couple of braces, say 1 in. x 2 1/2 in. on edge under the front and back decks running crossways of the boat even though your thinking of useing 3/4 in. plywood. Glass the decks just like you would the floor deck of the boat.
You can use epoxy thickened with a fairing filler to get the look you want at the rubrail area, then if it's necessary you can lay a layer of finishing cloth down.

 

[ondarvr]

Re: Flats boat PROJECT....Updated w/pics!

The vertical wall needs to be no more than 3/8 ply and the top no more than ?. You don?t need to run ? strips all the way around the front, just a few blocks will do, all you need is just something to hold the sheet of ply up until you glass the top side of it. I normally reach in through the hatch and run a strip of glass around where you want the wood blocks, this eliminates the possibility of rot. A thin layer of cloth should be used inside and out on any compartments like you?re making in the bow. These tend to hold water even with drains, when you have a closed compartment it turns into a steam box in hot weather, heated water vapor can migrate through almost anything, the extra thickness and strength of the cloth will help the ply last much longer.

If you want the insides smooth, then fair them, it?ll be much lighter and whatever you cover them with would need to be faired anyhow.

For the top cap make a V shaped mold out of plywood and pre-form the parts, then cut them to fit. One side of the V will be the flat top, the other angle will be a gusset for support, this hollow channel can also be used to run wiring through. Make them thin and then glass over them once they?re in place. Light, strong and no wood or foam. More details on making them can follow if you decide to use this method.

 

[john51277]

Re: Flats boat PROJECT....Updated w/pics!

For the top cap make a V shaped mold out of plywood and pre-form the parts, then cut them to fit. One side of the V will be the flat top, the other angle will be a gusset for support, this hollow channel can also be used to run wiring through. Make them thin and then glass over them once they?re in place. Light, strong and no wood or foam. More details on making them can follow if you decide to use this method.

I don't understand this method. The way I understand it is to make a mold and fiberglass it and then use it as the cap? Are you talking about the sides only? If so, this makes a little more sense. I can see making the "V" channel maybe 4" on one side and 6" on the other and it would be flat on top, angled for support (like the old window A/C units) then glass it the top and bottom. Would make for a clean look too.

 

[ondarvr]

Re: Flats boat PROJECT....Updated w/pics!

This can wrap all the way around the bow, the pre-made sections can be slit most of the way through and will then flex enough to follow the curve, remember they will be thin when you make them.
This cap section will be completely glassed over after it's in place, this will cover all the slits and bring it up to the strength needed for standing on.

You could make a mold for each side, but that entails much more work.

The mold can be a couple of pieces of plywood, you can use cellophane packing tape to cover the plywood for an easy release, wax can be used also, just wipe it on heavy and don?t take it off. Make the inside of the V on the part the mold surface, this would be the outside of the plywood V, it will be out of sight and the outside is going to be glassed over anyhow.

 

[john51277]

Re: Flats boat PROJECT....Updated w/pics!

Im starting to like that idea man. I can just make it 4' long and make up two of them. I would only have to make a few casts on this and I would be done. Thanks for the great idea. I don't know what I would do without you guys. (maybe sink)

It sounds like it will be pretty easy. I will post results as I go.

What about using cardboard with cellophane on it?

 

[ondarvr]

Re: Flats boat PROJECT....Updated w/pics!

For a one off part cardboard may work, but it would be difficult to make it keep its shape for even one part and you need to make several. Remember, you don't need to keep an exact V shape, you can modify it to suit your needs and use any size radius you choose. It does need to have a nice round radius so the glass can easily conform to the shape though.

 

[john51277]

Re: Flats boat PROJECT....Updated w/pics!

Ondarvr, thank you for the idea. I really liked what I imagined with that in place. After I got home from work, cooked dinner, and rested, I built a 4' long "mold" for the gunwales. It will be perfect for what I was wanting. I ripped some ply down and screwed them together. I did not measure it, i just eyeballed it. I did hold it up and it will have just a slight angle toward the outside. I used cellophane to cover the ply and I used some cloth I had lying in the scrap bag. I have switched to poly now. I have about 3 gallons from when I started the project. I did grind the corner nice and round to keep the glass from having bubbles when i add a layer or two. I will have to use this mold approximately 6-7 times. I guess I will try mixing the pots a little hot to help with time. Should I use a layer of 1708, or CSM on top of this once it sets up??

Here are some pics.

 

[ondarvr]

Re: Flats boat PROJECT....Updated w/pics!

One layer of 1708 should do it, after the first one is in place you'll know if it's enough

 

[john51277]

Re: Flats boat PROJECT....Updated w/pics!

I had another question pop into my head as I was looking at the project last night. Should I lay the 1708 ontop of the cloth that is on the mold now, or wait and tab the glass to the hull and then use the 1708 over it after I tab ot to the hull??? I would think I should tab the light cloth down and then lay the 1708 over that to secure it all to the hull.

 

[ondarvr]

Re: Flats boat PROJECT....Updated w/pics!

Make the parts as thin as possible and still be able to be handled, the bulk of the laminate should be applied after it's on the boat.

 

[john51277]

Re: Flats boat PROJECT....Updated w/pics!

I had to put a layer of CSM ontop of the thin cloth. I don't think it would have held shape well with the wet 1708 on it. I will use the CSM only for the next mold to see how it does.