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Introduction As a material for boat building, fibreglass has gained in popularity over wood and metal in both developed and developing countries, mainly because of the relative simplicity of construction, the ability to produce many identical hulls from a single mould, and the ease of maintenance of the boats themselves.

Fibreglass boats are completely watertight, rot-proof and resistant to borers. Disadvantages of fibreglass stem from the health risks associated with inhalation of fibre dust during construction, and the fact that the boats are slow to degrade and disposal at the end of their fiberglass boat building pdf zip code is difficult.

Fibreglass is a term used to describe Fibre Reinforced Plastic FRPa material consisting of glass fibre impregnated with resin. Typically, a hardwearing surface is created with the fiberglass boat building pdf zip code of a gel coat, strengthened by layers of fibreglass mat impregnated with resin. The required strength is achieved either by using several layers of mat or by using a thicker gauge of mat.

Materials and equipment The key to fiberglass boat building pdf zip code high quality boats is a good mould - a mirror image of the finished hull, which is also a fibreglass construction cast from either a plug, which is wooden replica of a hull, or the hull of an existing boat. In Sri Lanka, it is almost always an existing hull that is used to create the mould. Once the mould is created, it can be used to build hundreds of boats, which will have precisely the same shape as the original boat or plug used to create the mould.

Therefore, it is very important that a good boat fiberglass boat building pdf zip code the perfect hull shape is selected for this purpose. The better the plug, the better the mould and all the boats that come out of it. For larger vessels the plug and mould building is repeated for the deck and interior moulds.

Company Reg. Charity No. Glass fibre Glass is processed into filaments then woven or chopped and supplied in rolls of matting. The thickness of the cloth or mat varies with the weight of the glass in grams per square metre.

Type E glass should be used for tropical marine use. Reinforcement materials are supplied in rolls sealed in polythene bags inside cardboard boxes. On delivery the material should be checked for contamination by dirt, oil or water.

If spoiled, it is unusable. After checking, the rolls, they should be re-sealed to prevent contamination by high humidity. If damp, the bonding between the resin and mat are weakened.

Chopped strand mat CSM The continuous filament is held together with a binder to form a continuous sheet of chopped strand mat of variable thickness. One side of the material is slightly smoother than the. It is the rougher side which should be placed down when laminating. WR has a high tensile strength and also gives a higher glass per unit volume ratio than CSM, which means less resin is needed, and therefore is cheaper to use.

Approximate resin to glass ratio for CSM is 2. WR is rarely used in vessels of less than 6 m. CSM laminates are normally adequate for smaller boats. It is used to support a thick gel coat or to produce a smooth finish on the innermost layer of a laminate. Core mat This is a course mat that is specified by thickness rather than weight. It is used only for specific areas which require extra strengthening. Resins All resins should be stored in a cool, shaded and ventilated place.

The usual shelf life for resin is given as 6�12 months, but it can be used as long as it is liquid. Pre-accelerated resins have a shorter shelf life than pure resin. Lay-up or laminating resins The laminating resin a translucent liquid of pale colour provides the medium within which the fibreglass mat is bedded.

The resin is usually supplied in litre drums, but can also be bought in smaller quantities from retail suppliers. Gel coat resin The gel coat resin is a more viscous liquid. When cured, the gel coat forms the shiny, smooth, weather resistant outer surface of the hull. Resin putty This material is used as filler, or for bedding deck fittings or filling internal corners on joints which require bonding. Since it is composed mostly of a filler powder, which is water absorbent, it should not be used on underwater surfaces unless based on an epoxy resin.

A coating of PVA is used to prevent the mould from sticking to the plug or finished hull. Catalysts and accelerators To cure hardenresin requires a catalyst and an accelerator.

Resin can be ordered with or without the accelerator pre-mixed. Pre-accelerated resin is recommended because the supplier is able to make a more thorough mix; fiberglass boat building pdf zip code it is one less step for the user. Fiberglass boat building pdf zip code using un- accelerated resin, the accelerator should be thoroughly mixed in. Accelerator and catalyst must never be mixed directly together as this could cause an explosion.

Material Quantity kg Mirror Glaze Wax 0. Mixing resin or gel coat Resin is stored in drums in a cool, shaded place, preferably in a separate resin room.

There should be a drip tray beneath the tap. Between the tap and the tray will Building Your Own Fiberglass Boat Pdf be enough room to place a 5�10 L plastic bucket, which can be filled with resin for use by a laminator. Every two days, the drum should be rotated by and the tap removed and cleaned with acetone, to prevent blockage. Outside the fiberglass boat building pdf zip code room should be a two separate store cupboards for catalyst and for accelerator.

Accelerator can be added during the preparation stage and mix well with a clean, disposable wooden stick. The amount of accelerator added will be determined based on the weather conditions humidity. Catalyst is only added at the very last moment before laminating begins, when everything else is ready. Both these additives are supplied in 20 or 5 L plastic drums not in steel containers because resin reacts with Boat Building Epoxy Zip Code rust and are used to refill 1 L plastic bottles fitted with a graduated pourer for final mixing.

In the case of gel coat, a colour pigment will have been added to uncoloured gel coat according to supplier's mixing ratios. Standard white pre-pigmented resin is widely available as it is the most popular hull and superstructure colour. Preparing the mat The task of storing and cutting the mat may be allocated to one labourer who then becomes skilled at this task.

For preparation, a cutting table is needed see picture with a vertical rack for the rolls of different types of reinforcement from which appropriate lengths can be drawn and cut and then re-rolled and labelled with a felt tip pen to indicate to the laminators what it is.

It is good practise to use a plywood template for each section of mat needed. Lengths up to 10 m can be prepared on a shorter cutting table by folding the reinforcement. The Credit: Practical Action South Asia table edge should have graduations at 10 cm intervals to ensure precise measurement.

A sharp knife is needed for cutting and since glass reinforcement blunts steel blades very quickly, they should be sharpened. A straight edge is needed to cut the fiberglass boat building pdf zip code to length. An aluminium fiberglass boat building pdf zip code is Boat Building Companies In Cape Town Zip Code best as it is light to handle and does not contaminate the cloth. For cutting curves, a felt fiberglass boat building pdf zip code pen or chalked line can be drawn for guidance and the cut made freehand whilst allowing a 10 cm margin.

Industrial quality scissors may also be of use. Preparing the plug To begin, place the plug or existing hull being used to create to mould upside down on a level floor, and make sure the plug is absolutely level using a spirit level or transparent flexible tube filled with water.

At the deck edge, which is in this case near the floor, attach a plywood flange so that later during the moulding process, gelled Fibreglass can be trimmed back to leave a solid laminate with a clean cut edge. If the plug is wooden, cover the plug with a Fibreglass skin.

Fiberglass boat building pdf zip code layer can then be filled where necessary with resin putty to remove the shallow indentations, which will show up once the fibreglass skin is consolidated. Remove fiberglass boat building pdf zip code irregularities by grinding or by hand sanding.

Repeat this process of hand finishing until the plug is smooth enough to receive a layer of hard tooling gel coat. This especially formulated gel coat is the beginning of the coating, which will eventually give the polished surface from which the mould will be lifted.

The plug and mould gel coat should be black in colour, to contrast with the finished hull. There is no shortcut at this stage. The more time that is spent hand sanding the plug with wet and dry sandpaper, the better the plug will be. After applying the gel coat, further filling with resin putty and sanding may be necessary for a good finish.

In some cases the gel coat layer on the plug is omitted and only cataloy paste is used to fill imperfections.

Finally, polish with rubbing paste and then with 5�7 coats of non-silicone wax to give a brilliant fiberglass boat building pdf zip code, before applying a coat of PVA release agent, which is the last step before the mould itself is begun. Five workers would take at least a week for the final preparation of a plug for a 10 m hull. Making the mould If the shape of the hull is such that the mould has acute release angles, a split mould, rather than a one-piece mould, is necessary.

The two fiberglass boat building pdf zip code more pieces of the mould will be bolted together at a flange. To create the flange, a pattern of it has to be made on the plug on each side of the joint line. It is possible to use the first mould flange as the pattern for the second half. This will provide a very accurate joint and will allow boltholes to be through drilled in situ before release.

To build the mould, first, a uniform layer of gel coat should be applied fiberglass boat building pdf zip code the plug, using paint brushes with unpainted wooden handles or a high-pressure spray gun. In tropical fiberglass boat building pdf zip code this mixture will set hard in minutes, so only the amount required for the immediate job at hand should be prepared. For best results, panels of surfacing mat should then be laid down to create a smooth skin.

Once the panels are ready the resin should be prepared as. If a brush is being used to impregnate the fibreglass mat, short jabbing motions of the brush should be used. Once the resin has been applied, it can be spread using a washer- type or treaded roller, which helps to spread the resin out Credit Practical Action South Asia.

Leave for hours until set and cooled. Next, apply a layer of CSM. The panels of CSM should be cut to overlap each other by inches. Te resin should then be prepared and applied and rolled as. A layer fiberglass boat building pdf zip code core mat may also be added sandwiched between layers of CSM.

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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 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.

They are water resistant, do not rust or corrode, are low maintenances and durable. They perform the way wooden boats can't. With the best fiberglass and building techniques developed by SSF engineers, it is easier than ever to build boats. Qijing is a town near Kaohsiung located in southwestern Taiwan. Therefore, Taiwan boat builders' strong customization and innovation yacht design capabilities have attracted wealthy people worldwide.

In SSF, the design team, with 43 years of boat design experience, designs every client's boat based on their requests. The 3D and 2D boat design contains exterior styling sketches and renders, interior layouts and general arrangements.

When the specific designer is assigned, SSF works with architects to assure the overall design complements. When building moulds, it is critical to ensure every wood piece is cut precisely. In mould making, thin strips of wood are placed over a mould in layers. A computerized saw cuts wood pieces, and they are used for the moulds for the fiberglass boats.

Mold making is similar to construction of a fiberglass boat, except it involves the use of epoxy or polyester resins. It takes more than a year to design and construct a mould, and the mould must be perfect in order to make a cast of a boat. Fiberglass is the perfect material for building boats because it is corrosion resistant, maintenance free, stretch free and perfect for making lightweight, sleek, fast and strong boats.

SSF uses high quality fiberglass to assure the lamination process is done properly. There are various sizes and weights of fiberglass. Each fabric is made by fiberglass and wide knitted within certain patterns including biaxial, triaxial, and uni-directional knitted fiberglass.

There are also woven and matt fiberglasses with different weights. When laminating a boat, the boat is covered with fibreglasses at a 45 degree or 90 degree angle to enforce its strength and toughness. Dynel cloth is also utilized for adding abrasion resistance. Laminating epoxy is spread all over the entire boat as soon as the fiberglass cloth is evenly laid down. The procedure is repeated until the desired thickness if achieved.

To assure maximum waterproofing, isophthalic gelcoat and layers of mats are applied. After lamination is done, the casting is removed from the mould, and the mechanics start to work on the holes of the boat, including windows, hatches, wood trims, lighting, opening ports, electrical circuits, etc. 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. Personal Watercraft for Sale View All. Liked it? Share it! Facebook Twitter. He also served as managing editor at Offshore and associate editor at Cruising World.

Charles has logged more than 40, miles as an offshore sailor, including six transatlantic passages and some single-handed passages. His blog posts appear courtesy of his website www. Boat Reviews. Start Up Staff. Boating Guides. Boat Buyer's Guide. Boat Seller's Guide. Spring Commissioning for Your Boat.





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