The Gougeon Brothers On Boat Construction . Wood and WEST SYSTEM Materials .

Contents

Acknowledgements

1. Introduction.............................................................. 1
2. Before You Build ......................................................... 4
    Should You Build Your Own Boat? ......................................... 4
    Choosing the Right Boat ................................................. 6
    Boat Plans .............................................................. 6
    Modifying Plans for WEST SYSTEM* Materials .............................. 7
3. Estimating Materials and Labor ........................................... 9
    Rough Estimates ......................................................... 9
    Detailed Estimates Hull Costs ......................................... 9
    Detailed Estimates Hardware Costs ..................................... 12
    Detailed Estimates Labor .............................................. 13
4. Tools and Boat Shop ...................................................... 15
    Gougeon Brothers Power Tool Inventory ................................... 17
    The Boat Shop ........................................................... 20
    Temporary Shelter One Option .......................................... 21
5. Wood as a Structural Material ............................................ 25
    Engineering for Wooden Boats ............................................ 25
    Wood Strength ........................................................... 27
    Wood Stiffness........................................................... 29
    Wood and Moisture ....................................................... 31
    Moisture and Physical Properties ........................................ 32
    Wood/Epoxy Composites.................................................... 32
    Dry Rot(and Other Vermin) ............................................... 34
6. Buying Wood .............................................................. 37
    Quality What to Look For .............................................. 38
    About Veneer and Plywood ................................................ 39
    Buying Veneer ........................................................... 39
    Buying Plywood .......................................................... 40
7. WEST SYSTEM Products ..................................................... 42
8. Safety ................................................................... 51
    Boat Shop Safety Detailed Information ................................. 53
    How to Use WEST SYSTEM Epoxy ............................................ 54
    Solvents ................................................................ 55
    Wood .................................................................... 56
    A Note on Safety ........................................................ 57
9. Laminating and Bonding Techniques ........................................ 59
    Principles of Laminating Lumber ......................................... 59
    Preparing Stock for Laminating .......................................... 60
    Forms for Laminating .................................................... 60
    Using Core Materials .................................................... 63
    Bonding with the Fillet ................................................. 67
10. Scarfing ................................................................ 72
    Scarfing Lumber ......................................................... 72
    Scarfing Plywood Panels ................................................. 76
    Scarfing in Place ....................................................... 79
    Scarfing to Reduce the Scrap Rate ....................................... 80
11. Coating and Finishing ................................................... 81
    General Coating Guidelines .............................................. 81
    WEST SYSTEM Pigments and Other Additives ................................ 84
    Flocoat Procedures ...................................................... 85
    Primers ................................................................. 86
    Paints .................................................................. 87
    Clear Coatings and Natural Finishes ..................................... 88
    Applying Paint and Varnish .............................................. 89
12. Synthetic Fibers and WEST SYSTEM Epoxy .................................. 91
    Fatigue Behavior of Synthetic Fibers .................................... 92
    Common Uses for Fiberglass Cloth ........................................ 92
    Surface Preparation for Reinforcing Fabrics ............................. 93
    Applying Fabric ......................................................... 94
    Applying Unidirectional Graphite Fibers ................................. 95
13. Lofting ................................................................. 97
    The Table of Offsets .................................................... 98
    Materials for Lofting ................................................... 98
    Laying Out the Grid ..................................................... 100
    The Sheer Line .......................................................... 102
    The Deck Line ........................................................... 104
    Body Plan Sections ...................................................... 104
    Fairing the Longitudinal Lines .......................................... 106
    Lofting Hull Components ................................................. 108
    Developing an Angled Flat Transom or Bulkhead ........................... 109
    Curved Transom Development .............................................. 110
    Subtracting Planking Thickness .......................................... 112
14. Making Mold Frames and Permanent Frames ................................. 115
    Planning Permanent Frames ............................................... 115
    Mold Frames ............................................................. 116
    Transferring the Shape .................................................. 116
    Assembling the Frames ................................................... 119
    Permanent Frames ........................................................ 122
    Precoating and Prefinishing ............................................. 123
15. Setting Up .............................................................. 125
    The Centering Cable ..................................................... 125
    Anchoring Blocks......................................................... 125
    Setting Up .............................................................. 127
    Nailing and Screwing Legs ............................................... 130
    Permanent Bracing ....................................................... 131
    Beveling ................................................................ 131
    Fairing ................................................................. 132
16. Keels, Stems and Sheer Clamps ........................................... 133
    The Keel/Stem Assembly .................................................. 133
    Planning the Keel/Stem Lay-up ........................................... 133
    Laminating Forms ........................................................ 135
    Joining Keel and Stem Blanks ............................................ 136
    Installing the Keel/Stem in the Set-up .................................. 137
    Beveling the Keel/Stem to Receive Planking ................... .......... 137
    The Keelson ............................................................. 139
    Centerboard and Daggerboard Cases ....................................... 140
    Laminating Sheer Clamps ................................................. 141
17. Laminated Hulls A General Discussion .................................. 143
    Laminated Hulls ......................................................... 143
    Hot and Cold Molding .................................................... 143
    The Mold Method ......................................................... 145
    The Strip Plank Method .................................................. 145
    The Stringer-Frame Method ............................................... 146
    Wood for Laminating ..................................................... 147
18. The Mold Method: Building the Mold ...................................... 149
    Setting Up the Mold ..................................................... 149
    Planking the Mold ....................................................... 150
    Fastening Ribbands to Mold Frames ....................................... 152
    Finishing the Mold ...................................................... 153
19. The Mold Method for Laminating Hulls .................................... 155
    Preparing the Stock ..................................................... 155
    Inserting and Removing Staples .......................................... 158
    Applying the First Layer of Veneer ...................................... 160
    Spiling ................................................................. 161
    Applying WEST SYSTEM Epoxy .............................................. 163
    Applying the Second Layer of Veneer ..................................... 165
    Mechanical Spiling....................................................... 166
    Applying the Third and Succeeding Layers ................................ 167
    Applying the Final Layer of Veneer ...................................... 168
    Final Fairing ........................................................... 169
20. The Strip Plank Method for Laminating and Strip Composite Construction .. 172
    Setting Up for Strip Planking ........................................... 172
    Stock for Strip Planking ................................................ 173
    Applying Strip Planking ................................................. 174
    Edge Fastening .......................................................... 176
    Veneer Laminations ...................................................... 177
    Final Finishing ......................................................... 178
    Strip Composite Construction ............................................ 179
    Building a Stripper Canoe ............................................... 180
    Strip Composite Components .............................................. 181
21. The Stringer-Frame Method for Laminating Hulls .......................... 182
    Notching Frames for Stringers ........................................... 185
    Fitting and Fairing Stringers ........................................... 185
    I-Beam Frames ........................................................... 187
    The First Lamination .................................................... 189
    Installing the First Layer .............................................. 191
    Cleanup ................................................................. 193
    Applying the Second Layer ............................................... 193
22. Hard Chine Plywood Construction ......................................... 196
    Frame Assembly .......................................................... 196
    Setting Up .............................................................. 198
    Fitting Panels .......................................................... 200
    Applying Panels ......................................................... 202
    Composite Chine Construction ............................................ 203
    Final Fairing ........................................................... 204
23. Building and Developing Compounded Plywood Hulls ........................ 206
    Constructing the Keel Joint ............................................. 210
    Folding Up .............................................................. 212
    Bulkheads, Frames and Deck Beams ........................................ 216
    Fairing and Finishing ................................................... 218
    Design Guidelines for Model Building .................................... 219
    Building the Model ...................................................... 222
    Using Fiberglass Cloth on Compounded Plywood Models ..................... 225
24. Interior Construction ................................................... 227
    Installing Interior in Set-Ups .......................................... 228
    Installing Interiors in Upside-Down Hulls ............................... 228
    Installing Interiors in Upright Hulls ................................... 229
    Bulkheads and Partitions ................................................ 233
    Cabin Sole (Floor)....................................................... 234
    Icebox Construction ..................................................... 236
    Tanks ................................................................... 236
    Windows and Ports ....................................................... 238
    Electrical and Plumbing Systems ......................................... 239
    Interior Final Finishing ................................................ 239
    Painting and Varnishing Interiors ....................................... 241
25. Deck Construction ....................................................... 243
    Developing Deck Camber .................................................. 245
    Deck Framework .......................................................... 246
    Laminated Deck Beams .................................................... 248
    Cockpit Construction and Installation ................................... 248
    Decking Over ............................................................ 249
    Sandwich Constructed Decks .............................................. 251
    Blocking for Hardware ................................................... 253
    Cabin Construction ...................................................... 254
    Deck Finishing .......................................................... 255
    Teak Veneer Deck System ................................................. 258
26. Hardware Bonding ........................................................ 260
    Shear Load and Fasteners ................................................ 262
    Procedures for Bonding Fasteners ........................................ 264
    Preparing Metal Surfaces for Bonding .................................... 266
    Procedures for Bonding Hardware ......................................... 268
    Casting Hardware in Place ............................................... 269
    Bonding Ballast Keels to Wood Hulls ..................................... 271
    Bonding Through Hull Fittings in Tubes .................................. 276
Appendix A: Wood Data ....................................................... 277
Appendix B: Material Fatigue ................................................ 282
Appendix C: Scantlings for Well-Known Boats Built with WEST SYSTEM Products.. 286
Appendix D: Impact Testing on Reinforced Laminates .......................... 288
Selected Bibliography ....................................................... 290
Index ....................................................................... 291