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Foam sandwich is a well proven material, light and strong. It is particularly well adapted to the building of one-off hulls. It is well suited to amateur boat building because it does not require a female mold or any special equipment. We will describe what is commonly called the open mold method. Once you master the open mold technique, you can graduate to vacuum bagged or infused hulls.

We will focus on the techniques specific to foam sandwich. Please refer to general boat building books for details about building steps common to all methods such as strongbacks set up, bulkheads alignment, outfitting. Most books about boat building describe the techniques we use in great. The techniques we show are common to all hull types, power fpam sail.

Editor note: the current up to date version of this text can be found in the bateau2. After completion of the hull, the internal components will be added. The deck will be built the same way as the hull. Those familiar with our plywood epoxy stitch and glue composite method will recognize the procedure. The differences in constrution methods between plywood composite and foam sandwich result from the difference in stiffness between the two materials.

Plywood is stiff and will require less molds. In plywood cored composite, the frames and bulkheads foam fiberglass boat construction guide often be used as molds.

In favor of the foam is the ease of cutting and the flexibility: no foam fiberglass boat construction guide to fight the core material while bending the panels or planks.

Foam is more flimsy fibeglass must be supported fiebrglass a more dense structure. We will use either closely spaced molds or battens on molds or a combination of the two. A major difference is the lamination schedule. The fiberglass skins used in foam sandwich are much thicker than in plywood sandwich. This file will focus on the building of the hull, deck and structural elements. For the accommodations, systems installation and paint please see our on line tutorials or refer to specialized books and supplier's technical documentation.

The specifications for the jig such as the number and spacing of molds foam fiberglass boat construction guide the use of battens depends on the type of core materials: foam sheets or foam strips. The foam can be baot in large sheets the size of a plywood sheet. Boats fibreglass hull panels close to developable surfaces vuide use plain sheets of foam. Scored or contoured foam is foam with deep cuts on one or the two sides.

It conforms easily to almost any shape. The battens or slats are required to support the very flimsy sheets of scored foam or ffoam shape the solid foam accurately. Before installing the foam over the battened molds sometimes called a slat moldsome builders cover the whole fibeerglass with a sheet of plastic to prevent the resin from leaking through gaps and bonding to the jig.

Foam fiberglass boat construction guide fasteners are removed after the hull is turned. Headless nails can be pulled through the battens from inside. In some cases, nails with buttons are required. Buttons are small pieces of plywood acting as a washer.

The slat mold method is foam fiberglass boat construction guide most common in professional boat coonstruction. A good slat mold can be used many times. It is more labor intensive than strip Foam Core Fiberglass Boat Construction Manual planking methods not only because of the slats but to foam fiberglass boat construction guide the large panels requires two men. Jacques Mertens www. Thanks to our builders who volunteered to proof read for comprehension and grammar, in particular Glover Housman.

How to build a foam sandwich composite boat Foam Sandwich Manual from bateau2. These notes will describe step by step foam fiberglass boat construction guide to constructino a boat in foam sandwich composite. The notes below are not foxm comparing materials, we focus exclusively on building. Appropriate foams for the methods we describe below are Divinycell, Klegecell, CoreCell and Airex We will only gujde epoxy as resin: no polyester or vinylester.

Copyright Jacques Mertens. Introduction :: Foam strip planking :: Step by step :: Drawing tiberglass molds :: Setting up the jig :: Planking the Foam Fiberglass Boat Construction Technology jig :: Inside fiberglass :: Inside structure, building foam fiberglass boat construction guide parts on a table :: Deck :: Details, attachments, fittings.

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The subsequent day, The timber vessel skeleton have been meticulously grown drawn with a newbie foam fiberglass boat construction guide in thoughts.

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Foamboat Construction: Go from sketch to model to fullsize solid boat hull in easy steps using my FOAMBOAT method. Wrapping fiberglass over a pre-carved foam male mold is not new, it is regularly used to make custom surfboards. What I offer is a way to shape a mold that w. Overview of the hull building method: We will create a foam hull shape around a wooden jig, fiberglass the outside, flip the hull, remove the jig and fiberglass the inside skin. After completion of the hull, the internal components will be added. The deck will be built the same way as the hull. Jul Foam Core Fiberglass Boat Building Guide 15, �� The following video was posted by Cerny Yacht Design and features their foam core boatbuilding method. This method appears to result in hulls that are both lightweight and stiff. Another advertised benefit is the ability to create nicely shaped, rounded hulls, if desired.

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