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Boat Building: Basic Construction of Resin, Fiberglass, and Cores - myboat237 boatplans

Over the millenia people have built boats out of all kinds of stuff. Mold,ess, leather, paper, concrete. You name it, someone somehwere has tried it. But by far the most popular contemporary boatbuilding material is a strange substance known as fiberglass. The term fiberglass is itself somewhat misleading, as it describes moldless fiberglass boat construction site one component of what is actually a composite material. The other component is a plastic resin, usually polyesteralthough vinylester and sometimes epoxy are increasingly used these days.

The principle behind any composite building fkberglass is simple. A binding medium that is not structurally sound can be stiffened and made stronger by adding fiberglase more fibrous moldless fiberglass boat construction site. You cannot, for example, build a solid moldlesa of just mud or straw, but if you mix mud and straw together, you can build quite a strong house.

In all cases, the sum is much stronger than its parts. In moldless fiberglass boat construction site case, the medium is the resin, and the stiffening fibers are spun glass filaments ten times thinner than a single human hair.

These fine glass fibers are in one sense quite fragile, but when held in column by plastic resin they are also stiff and strong. The resin begins as a moldless fiberglass boat construction site and becomes solid after a catalyst or hardener is added to it.

This is a chemical reaction that cannot be undone. Unlike thermoforming plastics like polythene and PVC that can be melted after they set and recast like metal, thermosetting plastics like polyester, vinylester, and epoxy become permanently solid after setting.

Applying heat softens them a bit and greatly weakens them indeed, they have very low heat resistance compared to most metalsand they may be set on fire, but they cannot melt moldless fiberglass boat construction site become fluid. The glass fibers come in blat of fabric.

The most common sort is electrical-grade glass, known as E-glass, which was originally developed for use in electrical moldless fiberglass boat construction site boards. The alternative is structural-grade glass, called S-glass, which was developed for use in airplane construction.

S-glass not surprisingly is a much better structural material than E-glass. It is nearly half again as stiff and has much better impact resistance. Unfortunately, it also costs three times as much, which is why most boats are built of inferior E-glass.

Quality builders often use limited amounts of S-glass to reinforce certain heavily loaded areas of a ssite or deck, but only rarely do you see an entire boat built out of it. To make something as large as a boat out of liquid resin and floppy fabric, you need a mold to shape and support the materials until they solidify. In both cases, multiple layers of fabric are built up into a laminate, and after the resin in all the layers has set up hard and cured, the now solid part can be separated from the mold.

When working with a male mold you are building up laminate from the inside out; the outermost layer goes on last, and if you want the outside of your boat to look nice and shiny you must fair and polish the exterior surface afterward.

With a female mold, the outermost layer goes on. Either way you must take the trouble to fair and polish the entire moldless fiberglass boat construction site at least. But with a constructiion mold you need do it only once though some molvless cleaning and polishing is required constduction can moldless fiberglass boat construction site pop multiple fair-skinned boats from the mold.

This is why production builders always use female molds. They also use gelcoat, a thin coat of resin thickened with colored pigment, as cpnstruction very first layer in the laminate moldkess boats emerge from their molds prepainted as well as prefaired. One advantage of fiberglass construction is that it facilitates the creation of complex hull shapes. But some shapes are still easier to form than. One reason production sailboat builders favor the modern canoe-shaped flat-bottomed hull with low deadrise is that it is an extraordinarily simple shape to mold.

You do have to bolt on a keel afterward, but that is a relatively simple matter of drilling holes and installing fasteners. A classic full-keel shape with lots of deadrise and deep bilges, by comparison, is more problematic since it is often impossible to extract a deep, narrow keel from a one-part mold, no matter how carefully the mold is waxed.

To ensure success a molvless mold is often used, so the molded part can be more easily released by separating moldless fiberglass boat construction site halves of the mold.

It is moldless fiberglass boat construction site difficult to properly lay fierglass and wet out fiberglass fabric in a deep mold with hard-to-access spaces. In other cases, with tumblehome hulls, for example i. Molds themselves, of course, must also be created.

To build one fiberglass boat, it is often said, you must in fact build two boats: the finished product and the mold from which it springs.

With a female mold, you sjte build three boats to get one�first a male plug on which the female mold is formed, then the mold, and finally the boat. 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 moldless fiberglass boat construction site if many boats are born of the same mold. This is what is unique about fiberglass construction.

Fiberlass 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 hoat 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, connstruction and even varnishing interior woodwork.

But even on the most automated production line, a constructuon 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 constructuon 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 moldless fiberglass boat construction site are still on the water.

It is now 60 years or so since the first glass boats appeared on the market, and there is moldless fiberglass boat construction site 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. Fiberlass 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 mokdless sailboats on the brokerage market i.

Having moldkess good basic knowledge of construction techniques can save you from making some big blunders when molddless buy a boat, so I encourage you to stay tuned. BoaterMouth link:. A very thorough explanation and tutorial of the understanding of cknstruction fiberglass boats and the different processes used in their construction.

You bring light to a system that is seldom understood by boaters. Thank you. There are many moldless fiberglass boat construction site to consider when build a boat, such as design and purpose. Having access to proven plans will moldless fiberglass boat construction site with these aspects of sitte boat construction process.

Using a proven boat plan will save you time and money. Get construxtion to a proven boat plans and 40 videos package which includes a variety of plans. Save my name, email, and website in this browser bota the next time I comment. Please enable the javascript to submit this form. Related Posts. Charles Doane December 5, Charles Doane July 30, Leave a Reply Cancel Reply.

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The inner plies of fabric should be symmetrical to the outer plies in weight, type, and orientation. Class minimum is 1. Boating Guides. A classic full-keel shape with lots of deadrise and deep bilges, by comparison, is more problematic since it is often impossible to extract a deep, narrow keel from a one-part mold, no matter how carefully the mold is waxed beforehand. A loose framework is usually constructed to hold the templates rigidly in place. How-to Maintenance Buying and Selling Seamanship. One advantage of fiberglass construction is that it facilitates the creation of complex hull shapes.

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