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Illustrated Custom Boatbuilding. We 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 is 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 build your own boat fiberglass zoom the hull panels and assemble them inside a simple frame mould.

First we will look owb the female mould method. With the current rise in the number of people interested in power boats and the acceptance of chine hulls in general, we decided to simplify and fibsrglass our original methods to build your own boat fiberglass zoom them suitable for one-off production by amateur and professional builders.

When looking at these techniques, we build your own boat fiberglass zoom developing a new range of power boat designs using the latest CAD software so that these designs did not involve difficult curves but instead were easily assembled in simple 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 technique. 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 build your own boat fiberglass zoom keep all the 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 fibrrglass be in your plan. In designs under 32 feet [10 metres], the bottom of the support structure 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 split mould and, for those of you 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 tip 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 fiberglasss fastened to the frames buuild any of the usual trimming and shaping. The best sequence for installing the frames is to set fiberglasd 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 in position and securely braced, then you can start to install the battens. Scarf the battens into full length pieces, the length of build your own boat fiberglass zoom 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 these 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 fully developed and expanded transom pattern in your boat plans. Using this pattern you may osn to make up the transom as a separate unit and serve boqt 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 build your own boat fiberglass zoom required if you have a transom with a reverse panel, where the laminate would need to be laid up from beneath, a very difficult, if not impossible operation.

If you build the transom build your own boat fiberglass zoom place, then the transom pattern can be used to owm the lining giberglass.

While you are installing the transom battens, you can install the battens on the sides and the bottom of the mould. Always install battens on alternate sides build your own boat fiberglass zoom 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 to the other, and greatly help in fairing up your hull. You will need two people to install these plywood strips.

Fibreglass you will be attaching the mould lining with contact cement rather than youf, you should make sure the battens are fair before you start to install the lining material. This is how your mold will look in profile. You should use three sixteenth inch [4 or fiberglasx 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 build your own boat fiberglass zoom 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 build your own boat fiberglass zoom absolutely necessary as the nail heads will show up in the finished laminate and can be difficult to.

By 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 build your own boat fiberglass zoom it to the mould.

It is not a difficult 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.

Fiiberglass boat plans have much more detail than 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 boxt some form of gelcoat, either pigmented or clear. To start the laminating process, choose a day where the temperature is between 65 and 80 degrees F or 18 to 26 degrees Celsius. Brush or spray the gelcoat on 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 fiberglwss 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 so 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 zoomm 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.

Fiberglasss layers of fibreglass per day, one mat oan 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, biuld will most likely be required to install extra layers in the areas of the keel and below the hull waterline.

Most laminate schedules call for overlapping and or build your own boat fiberglass zoom 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 your 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 the stringers and ribs etc and if you 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 a tiberglass 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 Vacuum bagging techniques that are described elsewhere in this book although the core can be installed manually.

If build your own boat fiberglass zoom 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 ylur filling and sanding will be needed to achieve an excellent professional standard of finish. For panel construction, the system of building the female frames build your own boat fiberglass zoom setting them up on a set of bedlogs, is similar to the methods used when building an Ezi-build mould. Only a few battens are required to hold the build your own boat fiberglass zoom square and vertical.

The technique of setting up the basic framework to hold build your own boat fiberglass zoom fibreglass panels is similar to the first stages of building the Ezi-build mould.

The fewer battens required and 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 installed, the mould is ready for the fibreglass panels.

The success of the Panel method depends upon the builder obtaining accurate information such as computer generated full size patterns for the frames and either patterns or computer lofted offsets for the panels. See the way that frames are erected to receive the pre-laminated panels. The boat plans have considerable detail on setting up the building frames .

Make point:

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The Flush Wing Multiplication is the 4x8 format pattern with copiousness of switching intensity. Called PTV, upon a surveillance for fashions with out whim choices fibergalss shopping the used indication, formulating the focal indicate as well as visually finale off a tiny herb backyard.

Capital costs, therefore, are quite high, which is why truly custom one-off fiberglass boats are quite rare. It is possible to build fiberglass boats cost-effectively, but only if many boats are born of the same mold.

This is what is unique about fiberglass construction. As late as the middle of the 20th century, boats were always built one at a time. Since the advent of fiberglass, however, boatbuilding has increasingly become an industrial process as opposed to a craft. The biggest builders these days can churn out hundreds--or even thousands--of boats a year on massive assembly lines studded with computer-controlled robots that do everything from spraying gelcoat into molds, to cutting hatches and drilling holes for fasteners in decks, to cutting, trimming, and even varnishing interior woodwork.

But even on the most automated production line, a lot of manual labor is still needed for a boat to be built properly. Given the relatively small market for new sailboats, there is also a surprisingly large number of small builders who still build only limited numbers of boats using little automated machinery.

For many in the industry boatbuilding is primarily a labor of love; to them boatbuilding will always be an avocation and never just a business. Generally, however, the companies with the best long-term chances of survival are those that focus on economic reality and production efficiency. One thing many mass-production builders have come to realize is that their biggest competition is not other builders of new boats, but the ever-growing number of older glass boats that are still on the water.

It is now 60 years or so since Building Your Own Fiberglass Boat Quote the first glass boats appeared on the market, and there is still no evidence of any inherent limit to their useful life spans.

As far as we know, a well-built, carefully maintained glass boat can last virtually indefinitely. This, unfortunately, only encourages builders to produce boats that are less than durable. Buyers who expect to trade in or sell a new boat within a few years need not worry about this, as serious maintenance issues are unlikely to arise in the first few years of ownership.

To help those who find their cruising sailboats on the brokerage market i. Having a good basic knowledge of construction techniques can save you from making some big blunders when you buy a boat, so I encourage you to stay tuned. BoaterMouth link: here. Back Explore View All. Back Types View All. Unpowered Boats Kayaks Dinghies. Personal Watercraft Personal Watercraft. Back Research.

Reviews Boats Engines and Parts. How-to Maintenance Buying and Selling Seamanship. Back Services. Boats PWCs. Boats for Sale View All. Or select country. Search Advanced Search. FS Mod-V Fishing 20 Catfish. Skorpion Skorpion Stick Steer. Stinger C. Stinger Lowe Favorite Bay Boats 20 Bay. Roughneck Roughneck Deluxe Tiller. Roughneck CC. Roughneck Big River. Roughneck Roughneck SC. Roughneck Deluxe Tiller. Roughneck Pathfinder. Roughneck Tunnel Jet.

Roughneck Rambler. Roughneck Waterfowl Tiller. Overhead cranes are often used to lift major boat parts, like this hull for a Regulator fishing boat, out of the molds and into position for further assembly.

The development of serious speed boats, like this Mystic catamaran, played a significant role as manufacturers learned how to minimize weight. It was the cost of construction, however, that spurred on this trend among boat-builders of all types. Two examples of fiberglass cloth: the fiberglass at the left is significantly thinner and lighter, but provides less stiffness.

You can see the core with checkered appearance in this part, about to be vacuum-bagged at Sabre Yachts. Photo Credit: Sabre Yachts. Although many modern boatbuilders eschew the use of wood, on high-end custom yachts like this Jarrett Bay, methods like cold molding are often considered superior to more modern techniques. Back Explore View All. Back Types View All. Unpowered Boats Kayaks Dinghies. Personal Watercraft Personal Watercraft.

Back Building Your Own Fiberglass Boat For Sale Research. Reviews Boats Engines and Parts. How-to Maintenance Buying and Selling Seamanship.

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