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Illustrated Custom Boatbuilding. Constrcution recommend that you read this hardcover book - Order now and we will pay the postage. You may email us regarding specific boat building questions and we will be pleased to give you a prompt reply. In the meantime Please email me your comments on our site We have developed a 'cheap one-off mold' fiberglass boat building system that foam core fiberglass boat construction sim ideal for building larger powerboats.

There are two main Ezi-Build methods - one where you build an inexpensive female mould and lay up the hull in that mould and another where you pre-make the hull panels and assemble them inside a simple frame mould. First we will look at the female mould method. With foam core fiberglass boat construction sim current rise in the number of people interested in power boats and the acceptance of chine hulls in general, we decided to simplify and streamline our original methods to make them suitable for one-off production by amateur and professional builders.

When looking at these techniques, we were developing a new range of power boat designs using the latest Foam core fiberglass boat construction sim software so that these designs did not involve difficult curves but instead were easily assembled in foam core fiberglass boat construction sim one-off moulds. These new designs all reflected the ability of the computer to produce absolutely fair, developable hull surfaces suitable for turning flat sheets of fiberglass into attractive hulls.

Most of the original designs were directed towards steel or aluminium but the demand for similar fiberglass methods led us to develop computer lofted hulls with full developable surfaces and the result is the Ezi-Build corre.

This area should be as wide as the beam of the boat plus a minimum of one foot [mm]. The depth should be the depth of the hull, plus a minimum of 3 feet [1 metre]. This space will be the minimum required to construct the frames over the patterns. This procedure will be explained in your boat plans and should be easy to follow. Remember, that you are making frames for a female mould. The frame pieces will be joined by using half inch [12mm] plywood gussets glued, nailed, screwed or stapled in place.

Screws are strongest but staples are quickest and most convenient. Make sure conwtruction keep all foam core fiberglass boat construction sim gusset materials clear of the inner edges of the timber frames. Later, you may need to trim these inner edges with a plane and nails or gussets will interfere with this process. Build the hull frames in a way that provides an outer framework to support the whole mould structure details of which should be foam core fiberglass boat construction sim your plan.

In designs under 32 feet [10 metres], the bottom of the support structure Foam Core Fiberglass Boat Construction Year can be canted 45 degrees which will enable the whole structure to be tilted, side to side, for easy lamination. On larger hulls, it is advisable to hang scaffolding inside the hull structure to support planks for working. For one-off boats, the relatively cheap Ezi-build mould, which is easy to disassemble, has eliminated much of the need for the more compliCATAMARANed cors mould and, for those of foan who think that these methods present more work than is justified, compared to building a one-off hull over a male mould, let me assure you after having sanded many fibreglass hulls, I feel these methods are by far the best and fastest way to build a one off fibreglass power boat or multi chine sailboat hull.

A fibberglass on setting up the frames � if the frames forward of frame 5 are set up with their forward face on the station line and the frames aft of frame 5 are set up with their aft face on the station line, then most of the bevelling and fairing will be avoided. The battens can be fastened to the frames without any of the construcrion trimming and shaping. The best sequence for installing the frames is to set up the centre frame first, usually station 5.

Make sure this frame is truly vertical, using a plumb-bob hung from the centre line marked on the headstock. Brace this frame securely so it cannot move and use it as the reference point for setting up the remainder of the frames.

When all the frames, stem, centre line board and transom centre line board are foam core fiberglass boat construction sim position and securely braced, then you can start to install the battens.

Scarf the battens into full length pieces, the length of the hull plus a few inches for trimming. The batten width may vary. You should have a stock of wider boards of the correct thickness and then rip the battens to selected width depending on the requirements of your particular hull shape.

Allow foam core fiberglass boat construction sim battens and the sheerline battens to run a few inches past the stern location. Now you may install the transom section of the mould.

Camber boards are half checked at right angles to and on to the transom centre line board. Once the camber boards are in place, batten up the transom vertically. It is usually not necessary or advisable to nail the side and transom battens together, use plywood strips outside the battens placed near the intersection of the side and transom battens to hold the battens fair. You should have a doam developed and expanded transom pattern in your boat plans.

Using this pattern foxm may prefer to make up the transom as a separate unit and serve it up to the mould in one piece. If you make the transom as a separate unit, it can be at least partially laid up away from the main mould.

This is required if you have cor transom with a reverse panel, where the laminate would foam core fiberglass boat construction sim to be laid up from beneath, a very difficult, if not impossible operation.

If you build the transom in place, then the transom pattern can be used to cut the lining material. While you are installing the transom battens, you foam core fiberglass boat construction sim install the battens on the sides and the bottom of the mould. Always install battens on alternate sides of the centre line, working progressively on both sides. After all battens are in place, install fairing gussets or strips of one half inch [12mm] thick by four inches [mm] wide plywood, clench nailed on the outside of the battens, one or two strips between each frame.

The strips run from sheer to the chine and from the chine to the centre line. The strips will even out the battens and fair up one foam core fiberglass boat construction sim the other, and greatly help in fairing up your hull. You will need two people to install these plywood strips. As you will be attaching the mould lining with contact cement rather than nails, you should make sure the battens are fair before you start to install the lining material.

You should use three sixteenth inch bowt or 5mm] plywood or tempered hardboard or any other suitable sheeting material. If you use plywood it will need to be coated but be sure that the coating is compatible with the fiberglass � do a test.

From this stage onward work closely with your fibreglass materials supplier and take his advice on the correct wax and release agent to use on the mould. Nail only construxtion absolutely necessary as the nail heads will show up in the finished fjberglass and can be difficult to. Foam core fiberglass boat construction sim using the contact cement you will end with a clean inner surface of your mould.

Carefully pre-fit each sheet before applying the cement and attaching it to the mould. It is not a foam core fiberglass boat construction sim job to install the lining providing you work with some care. Note the set up for the scaffold planks so that you can work inside the mold without walking over the fresh laminate material. The boat plans have much more detail foam core fiberglass boat construction sim can be included.

Also, radius any areas where you need to have rounded corners. For this job, you can use body filler or any other polyester based material that is compatible with the fibreglass laminate you will be installing.

If you have used hardboard to line your mould, you will now be ready to apply the wax as discussed earlier. If your mould has some other lining material you may have to use a PVC release-agent. You should talk to your material suppliers about the most suitable.

We would recommend you use some form of gelcoat, either pigmented or clear. To start the laminating process, foam core fiberglass boat construction sim a day where the temperature is between 65 and 80 degrees F or 18 to 26 degrees Celsius.

Brush or spray the gelcoat conshruction to the mould surface where it should be applied at a thickness of 0. You can measure the thickness of the gel-coat by using a special gauge obtainable from your fibreglass supplier. Ideally, you should use a clear isothalic NPG gelcoat and back it up with a layer of surface tissue and vinyl ester resin.

This is important constructiob see your resin supplier about getting the right materials if you want to be sure of increased resistance to water permeation and avoid any possibility of osmosis, at a later date. You will need two or three helpers as you start to lay up the hull and it is advisable, for temperature control, to be at the same stage of lamination each day with each successive layer.

If the laminate overheats from applying too much material at one time, it may cause distortion and pre-release from the mould. Once the gelcoat and first layer of mat are in place you will have passed the most critical stage of your laminating process.

Providing you follow some form of temperature control, you should go on to complete the laminate without any problems. As mentioned earlier, always finish your laminating at the same part of your hull each day. Three willing workers can lay up a fifty foot [20 metres] hull in a few days.

Two layers foam core fiberglass boat construction sim fibreglass per day, one mat and one roving, is a reasonable amount to install at one go without causing the laminate to overheat. New resins are being formulated all the time so you must have the latest technical data and support from your materials supplier. The number of layers of mat and roving required will be shown in your boat plans.

After the layers that cover the whole hull surfaces are completed, you will most likely be required to install extra layers coee the areas of the keel and below flberglass hull waterline. Most laminate schedules call for overlapping and or interleaving the various layers in the areas such as the chine and keel, thus building up extra strength where it is required.

Again, we remind you to trim the sheerline of your hull each day. This will usually be done as work progresses and about an hour after the final layer for the day has been installed.

Once you have installed the basic laminate and any extra layers called for in foam core fiberglass boat construction sim plan laminate schedule, you should add any stringers, sole shelf, deck shelf etc and any other reinforcing members called for in your boat plans.

You should then install all the ribs, stringers, bulkheads and web floors before you remove the hull from the mould. After you have completed the installing of foam core fiberglass boat construction sim stringers and ribs etc and if foam core fiberglass boat construction sim do not plan to use the mould again, you may prefer to remove only the mould above the chine or water line, leaving the bottom section to act as a cradle.

Using an easily constructed inexpensive female mold any builder with the minimum of effort can produce fibfrglass boat hull with a professional finish. This Waverunner 65 has now been chartering in the Greek Islands for several years In either case, the best method to install the core is to use Boag bagging techniques that are described elsewhere in this book although the core can be installed manually. If you intend building a sandwich hull, please read the chapters on one off building, where you may pick up a few ideas on the handling of core materials.

The main advantage of using this technique is that a full mould is not required. You will retain the advantage that a minimum of finishing is required for the outer surface of your hull. Very little filling and sanding will be needed to achieve an excellent professional standard of finish.

For foam core fiberglass boat construction sim construction, the system of building the female frames and setting them up on a set of bedlogs, is similar to the methods used cpre building an Ezi-build mould.

Only a few battens are required to hold foam core fiberglass boat construction sim frames square and vertical.

The technique of setting up the basic framework to hold the fibreglass panels is similar to the first stages of building the Ezi-build mould. The fewer battens required coee the absence of a mould lining material, are the main differences between the Ezi-build and the Panel methods.

Additional bracing is used on the outside of the frame assembly and once the frames and the few battens are booat, the mould is ready for the fibreglass panels.

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