First picture is the underside of the deck, with reinforvement strips of fiberglass running along all joints. This also got a coat of epoxy.
Second picture is inside the hull. I've already done a saturation coat of epoxy, and laid done fiberglass in the front and back halves. If you look closely, you can see a gap where the two sheets of fiberglass didn't reach. I'm going to use the small section at the top of the picture to patch between both.
Looking into the bow, a little more fiberglass for reinforcement- and a small cardboard dam. This pocket at the very front gets completely filled with epoxy, which led me to several major problems. The first try, the dam broke and all the epoxy flowed down the inside keel. I managed to get most scooped up, but will have some sanding tomorrow. Second attempt was only slightly better. Instead of cardboard, used a small piece of wood cut to fit. It also leaked like a faucet, so kept trying to patch it up. Well, no matter how botched up it looks now, ther's nothing that can't be cured by sanding. That's why I invested in a random orbit sander and about 2 million sheets of sandpaper.
But I am close now, hope to have the deck on tomorrow. And I ordered some extra epoxy since I didn't want to run out when I was 95% completed.
After a saturation coat on the deck, I draped the fiberglass cloth across the top and let it hang several inches below the sheer seam.
Then, the hardest part, rolling epoxy into the fiberglass weave. This is probably the point in construction that requires the most attention to detail. Luckily, I've practiced on the inside and outside of the hull, so I've got it down pat now. After the epoxy sets for an hour, I trimmed at the top of the tape line shown. Lifting off the tape and the excess fiberglass, it leaves a nice edge. I'll sand this out and then start building up layers of epoxy on the deck.
Late July- I've had it out on the water several times, handles nice. Brought it back in the barn to paint the trim and varnish.
And now August, three coats of marine grade, spar urethane varnish (almost $50 for 1.5 liters). Bungee cords on the deck for hold downs and handles at the bow/stern for lifting and tie-down. Have it out several times, and I've invested in a good oar, a kayaking life jacket and a spray skirt to keep water out of the deck.
Overall price, to include the boat kit, shipping, parts, accessories, and detail work is probably close to $1400- not including labor. Would I do it again? Only if I had a heated garage or basement with power and temp control. But I am glad its done. |
