Roof

Chris wanted a cantilevered roof and looked at lots of boats and pictures to design the shape. He likes the look of the forward pitched windshield and made a mock up to get it exactly how he wanted.

 

 

 

He epoxied and fiberglassed all the pieces. He will cut out the windows later.

To make the rounded roof he epoxied together 4 layers of 1/8" plywood over a jig.  

Then he adds more layers of plywood to form a thicker edge and clamps it until dry.

Windows cut out, edges rounded over, epoxy, fiberglass, sanding sanding sanding.... We have a roof!

Straps hold the roof up while Chris attaches it to the boat with fiberglass and epoxy. 

 Then, more layers of fiberglass are added to make everything strong and hold it all together.  The shape is there!  But there is still a lot of work to do.

Cuddy Cabin

Time to design and build the cuddy cabin!

Clamps hold pieces in place until the epoxy cures.

More Floor

Sheets of fiberglass fabric are cut to size and epoxied to the floor deck one width at a time. This makes it strong and waterproof.

 

 

 

 

 

 

 

Once it is dry, the whole thing is sanded smooth. 

 

 

Chris cuts out pieces for the little upper deck, covers the undersides with epoxy, and attaches them.

 

 

 

 

Bulkheads and the Floor

Now that the boat has been flipped, the rest of the joints are covered in fiberglass and epoxy. Bulkheads are added to create compartments and to strengthen the floor.

The flooring is cut and sanded to fit from 3/4 inch Medium Density Overlay Plywood (MDO).

 

 

Then the flooring is removed and the underside is covered in epoxy.

 

When it is dry, the flooring is laid back into the boat and attached with thickened epoxy. The floor is screwed down to hold it until the epoxy dries, and then the screws are removed.