Todd's Mini-Tug Boat Building Journal

Wondering Where I Have Been??

2011-12-26T10:58:00.008-06:00

Well, I have actually been extremely busy building another large project. It is a RV-9A for Pat. I am almost completed with the painting and we are very close to moving it to the hanger.

Visor Drawn and Cut Out

2011-10-02T15:06:00.004-05:00

Today, I finally got to draw out and then cut out the visor out of tempered masonite. It will now need to be smoothed out along the contour and then fiberglassed on the bottom side before installing.

1.5 hours

Gunwhales Made/Seat Position Set

2011-08-20T15:40:00.006-05:00

A few days ago, I drew out the gunwhales on 1/4" plywood, and today I cut them out and fit them to the sides.

I also drilled the holes for the rear U-bolts and also drilled the holes for the front seats.

4.0 hours

Panel Holes Filled/Battery Box Box Made

2011-07-19T22:33:00.006-05:00

Tonight, I filled the holes that were used to attach the panel into place with epoxy/wood filler.

I also built a battery box made out of 3/4" x 2 1/2" Pine that the new plastic battery box will sit in and be tied down so it can't move during the wave action. I will then epoxy it into place inside the back seat area after it cures up. The wood battery box was also epoxied everywhere to begin sealing it.

1.5 hours

Panel Epoxied Into Place

2011-07-18T18:19:00.005-05:00

I finally decided to go ahead with the panel as I had previously built, after no other better designs were brought to my attention. The panel wasn't fiberglassed like all previous parts but was epoxied several times and sanded before being set into place. It should be plenty strong anyway. I will also apply another layer of epoxy when I add the layer for the interior of the boat.

3.5 hours

Panel Cut Out and Fitted

2011-07-09T13:59:00.004-05:00

Today, I cut out the panel pieces and fit them to the cabin front, quarter panels, and side panels. I don't know if I like the vertical piece that vertical. I think I would like it more tilted, but I will see soon and I will try to tilt it a bit by sanding down the horizontal piece.

2.5 hours

Side Decks Sanded and Epoxied Again

2011-07-06T17:51:00.005-05:00

Today, I sanded down my hand the side decks that were previously fiberglass taped and then applied a layer of epoxy.

3.0 hours

Side Decks Taped

2011-07-05T19:02:00.007-05:00

Today, I fiberglass taped the side decks on both the left and the right side after adding a fillet of epoxy/wood flour. I also filled the area between the front deck and the side decks to make a smoother transition once it cures and is sanded down a bit.

Also filled the holes on the interior right side and left side where the screws held the side decks into place. They will be sanded down and then the entire interior epoxied one more time before sanding and painting.

3.0 hours

Cabin Top Sanded and Cabin Exterior Epoxied/Right Side Deck Installed

2011-07-03T15:59:00.009-05:00

Today, I installed the right cabin side deck and sanded down the cabin top. I then applied a layer of epoxy on the entire cabin exterior and front deck.

5.5 hours

Left Side Deck Epoxied On

2011-07-01T17:29:00.004-05:00

I also epoxied on the left side deck today.

1.5 hours

Cabin Top Fiberglassed

2011-07-01T12:30:00.004-05:00

Today, I fiberglassed the top of the cabin top.

I also applied another layer of epoxy on the top of the transom.

2 hours.

Cabin Top Screw Holes Filled/Transom Final Shape

2011-06-28T20:34:00.005-05:00

Today, I sanded the transom to the final shape and applied a layer of epoxy to the exposed edge.

I also removed all of the screws in the cabin top and filled each one with non-thickened epoxy using a toothpick and then put a portion of a toothpick that was cut to size for each hole inside the hole. I let that set for about an hour then filled the top with thickened epoxy using wood flour.

3 hours

Cabin Top Epoxied/Side Decks Final Fitted/Transom Cut Out

2011-06-27T17:54:00.011-05:00

Today, I spent the time sanding down the sides of the cabin top to the sides and then epoxied it to the beams and the cabin quarter and front panels. I also final fitted the side decks and temporarily screwed them to the cabin sides and then removed them to epoxy in. I also marked and cut out the transom to the preliminary shape before sanding it to final shape tonight.

5.5 hours

Fiberglass Seams Sanded/Cabin Top Trimmed

2011-06-26T16:39:00.009-05:00

The last few days, I trimmed the cabin top to the side measurements. Today, I sanded down all of the previously fiberglassed seams, as I don't want that in the way after I epoxy down the cabin top. If I waited, it would be very hard to sand down some of those areas.

4 hours

Cabin Top Fitted

2011-06-17T18:30:00.004-05:00

The cabin top was fitted into place and screwed down, then marked on the bottom side to match the sides of the cabin.

I also applied another couple of layers of epoxy on all of the fiberglassed seams completed yesterday.

2.5 hours

Cabin Taped Up

2011-06-16T17:42:00.011-05:00

The other day, I sanded down all of the intersections between any panels and smooth out all corners in preparation for fiberglassing.

Today, I spent the day cutting out pieces of fiberglass out of all of the scraps to tape the cabin with, as I ran out of 3" fiberglass tape. I then epoxied all of the taped areas.

5 hours

Cabin Work

2011-06-10T08:45:00.002-05:00

Yesterday, I took out all of the screws and filled the holes with the epoxy/wood flour mixture. I also "tabbed" all of the sides where they meet each other so I can remove the wire ties and fiberglass tape all of the intersections.

I also radiused the rear edges of the cabin sides to the vertical uprights so I can fiberglass tape there as well.

Now comes a lot more taping and sanding. I will also be positioning the top into place and cutting it to the proper size.

3 hours

Cabin Installed Into Place With Epoxy

2011-06-08T20:06:00.006-05:00

Today, I installed the cabin verticals, sides, quarter panels and center panel, as well as the beams into place with epoxy.

3.5 hours

Cabin Sides and Side Decks Completely Fiberglassed and Epoxied

2011-06-04T09:47:00.002-05:00

This morning, I cut off all of the excess fiberglass and sanded down the cabin sides and side decks with 120 grit on the orbital, as well as all of the edges as they are very sharp. Then I applied another layer of fast epoxy.

2 hours

Fiberglassed Cabin Sides and Side Decks on Other Side

2011-06-03T14:18:00.002-05:00

The last few days I sanded down the previously fiberglassed cabin sides and side decks and applied a third layer of epoxy. I then cut out the large holes of fiberglass and turned them over to fiberglass the opposite sides.

3 hours

Fiberglassed Cabin Sides and Side Decks

2011-05-29T17:32:00.004-05:00

Today, I finally got around to fiberglassing the cabin side decks and cabin sides on one side.

1 hour

Cabin Beams and Uprights Fiberglassed/Boat Back Upright

2011-05-17T22:36:00.001-05:00

Today, I fiberglassed the cabin beams and the uprights on one side, as well as adding another layer of epoxy. I also turned the boat back right side up with the help of my son Matthew, to avoid scratching it any more than I did when I turned it upside down by myself. I will block it now that it is on the floor to avoid tipping it when I am inside working.

2.5 hours

Cabin Assembly Setup Complete/Side Decks Made

2011-05-17T22:30:00.007-05:00

Today, I finished setting up the rest of the cabin and fitting it properly. I also made the side decks that go between the hull side and the cabin side. The cabin front and quarter panels were cut to size and the windows cut out. The cabin sides were marked for the access holes.

6.5 hours

Cabin Assembly Started!

2011-05-16T22:31:00.008-05:00

Today, I set the uprights in position after sanding down a lot of the excess epoxy on the back corners of the seat boxes and then set the sides. I also put the beams into place along with the cabin front panel and one quarter panel.

5.5 hours

Cabin Beams and Uprights Sanded

2011-05-14T09:40:00.002-05:00

Yesterday, I cut off all of the excess fiberglass and epoxy on the cabin beams and uprights and sanded them down smooth with 40 grit on my orbital sander, which stopped working before I was done. I tried to take it apart and see what was wrong, but it will not work at all now.

3.0 hours

Cabin Beams and Uprights Fiberglassed on Other Side

2011-05-13T12:39:00.003-05:00

Yesterday May 12th, I fiberglassed the other side of the cabin beams and uprights. Today, I will start to put all of the cabin parts on the boat after cleaning up all of these parts with the sander.

2.5 hours

Cabin Beams and Uprights Fiberglassed/Boat Back Upright

2011-05-13T12:35:00.003-05:00

For some reason, this blog site deleted this blog and photos, so here it is again. Don't know what happened, but they were doing some maintenance on the site yesterday, so obviously something messed up.

On Tuesday May 11th, I fiberglassed the cabin beams and the uprights on one side, as well as adding another layer of epoxy. I also turned the boat back right side up with the help of my son Matthew, to avoid scratching the new paint. I set it on some moving blankets to avoid any damage.

2.5 hours

Sanded Newly Fiberglassed Parts

2011-05-10T21:42:00.002-05:00

Today, I sanded down all of the cabin front and quarter panels and the bottom side of the cabin top. I also routed the cabin beams on the bottom and got them ready to fiberglass.

3 hours.

Sanded Filled Knot Holes/Fiberglassed Top and Front Pieces

2011-05-09T18:33:00.002-05:00

Today, I sanded down all of the knot holes I filled the other day on the cabin top, front, quarter panels, and sides. I then fiberglassed the other side of the cabin front and quarter panels as well as the bottom side of the cabin top.

2 hours

Holes Filled in Cabin Parts

2011-05-06T17:44:00.005-05:00

Today, I filled all of the knot holes and checks in the cabin sides, cabin front and quarter panel and the cabin top.

1.5 hours

Cabin Front Panel, Cabin Quarter Panels Fiberglassed

2011-05-05T16:46:00.005-05:00

Today, I fiberglassed one side of each of the cabin front panel and the cabin quarter panels as well as doing the 2" fiberglass splice on the cabin top after removing the screws and filling the holes with epoxy/wood flour mixture.

2 hours

Cabin Front Panel, Cabin Quarter Panels & Cabin Top

2011-05-04T13:40:00.007-05:00

Today, I cut out the cabin front and quarter panels and the cabin top. I also cut out and epoxied on the two side pieces that extend the cabin top.

I also put another layer of epoxy on the taped areas on the bottom of the front deck to seal them up a little better before they are painted.

3 hours.

2nd Coat On The Bottom

2011-05-02T18:33:00.002-05:00

Today, I applied the second coat of red paint on the bottom of the boat and keel. I bought some naptha and added about 6 ounces to the gallon and that helped a little bit. I didn't sand it as I was going to do since almost no one will see the bottom after it is finished.

I also sanded down the taped areas inside under the front deck, as well as sanded the sides up there while it is still upside down. It is easier to sand that way than once it goes right side up.

2 hours.

Bottom Sanded and 1st Coat of Paint On

2011-05-01T18:59:00.005-05:00

Today, I sanded the keel and bottom down with 120 grit on the orbital sander, cleaned it with the vacuum, cleaned it with acetone and a clean rag, and then applied the first coat of red on them. It doesn't appear to be flowing out very well, so I may have to let this coat dry, sand it with 320 grit and then apply another coat thinned out with naptha. You can see that on the last photo.

4 hours

Taped Bottom of Front Deck/Layer of Epoxy

2011-04-29T12:58:00.005-05:00

Today, I fiberglassed taped the bottom side of the front deck, as well as put a layer of epoxy on the inside front sides of the hull right below the front deck and the bottom side of the front deck. It was easier to do this as the boat is now upside down.

2 hours

Applied Additional Layer of Epoxy on Bottom

2011-04-28T12:21:00.001-05:00

Today, I sanded down the bottom area with 120 grit on the orbital sander and then applied an additional layer of epoxy on the bottom area. The keel already has more than 5 or 6 on it, so it should be fine.

2 hours

Applied Epoxy on Keel and Bottom

2011-04-27T19:28:00.005-05:00

Slow Epoxy was applied on entire keel and bottom areas. The slow is definitely helping it flow out smoother better. I also applied an epoxy layer on the bottom side of the rear seat and along the edges to help seal them a little more.

2 hours

Sanded All Bottom Tapes and Hull Bottom

2011-04-27T14:02:00.005-05:00

Today and yesterday, I sanded down all of the fiberglass taped areas around the bottom, as well as the bottom of the boat. I will now apply two more layers of epoxy to seal everything, resand, and then paint the bottom.

5.0 hours

Rounded and Taped Bottom Corners; Sanded Down Keel

2011-04-25T21:16:00.012-05:00

Yesterday and today, I sanded down the center keel section and sanded down the forward corners of the hull sides to bottom area. I then fiberglass taped around the entire circumference of the bottom. I also made wood wedge shaped pieces to put in the area of the sides to fair everything in correct. I then added epoxy/wood mixture, let it cure, then sanded it down before fiberglass taping it over.

7.0 hours

Sanded Both Sides; Flipped Boat Over; Sanded Down Tapes

2011-04-23T17:41:00.011-05:00

Today, I completely sanded down both sides of the freshly epoxied hull. After that, which took over 3 hours and nearly ruined my orbital sander, I flipped the boat over (by myself, which was real fun) and began to sand down the taped areas left before. I also sanded down the right side hull that went below the hull bottom, and this will then be fiberglass taped.

6 hours

Left Side Hull Exterior Fiberglassed

2011-04-22T17:18:00.003-05:00

Today, I added the fourth layer of epoxy on the right side fiberglass and fiberglassed the left side, as well as adding another layer of medium speed epoxy.

6.5 hours

Right Side Hull Exterior Fiberglassed

2011-04-21T22:35:00.006-05:00

Today, I fiberglassed the exterior of the right side hull with slow epoxy to allow it to seep into the wood as much as possible. I will put two or three more layers of epoxy on in the next few hours.

3.0 hours

Sanded, Sanded, and Epoxied Again

2011-04-19T20:59:00.005-05:00

Today, I sanded down all of the areas I fiberglass taped yesterday, and then applied a layer of slow epoxy over all of the sanded areas, including the beaver-tail, rear seat, and some of the corners along the bottom of the hull.

3.0 hours

Rear Seat Taped, Beaver-tail Taped, Rear Seat Top Epoxied

2011-04-18T21:10:00.006-05:00

Tonight, I epoxied 4" fiberglass tape for the rear seat part to the transom and hull sides. I also put 3" tape on the beaver-tail edges, as well as put another layer of slow epoxy on the rear seat top to smooth it out a little more.

3.5 hours

Installed Rear Seat Back Piece

2011-04-18T14:35:00.005-05:00

Today, I epoxied in the rear seat back piece onto the transom and hull sides with thickened epoxy/wood flour mix. I will wait for it to set and then fiberglass tape it later.

1.5 hours

Rear Seat Doubler Epoxied on Bottom

2011-04-16T11:44:00.004-05:00

Today, I took off all of the clamps, sanded the corners a little bit to make it fit better, and then epoxied the bottom of the doubler.

30 minutes

Rear Seat Doubler Cut Out and Epoxied On

2011-04-15T23:25:00.005-05:00

Tonight, I cut out the rear seat from the part that will be epoxied onto the transom and hull sides. I then used the rear part to cut out a doubler from 1/2" plywood and epoxied them together. As you can see from the last photo, a lot of clamps were used to make sure they were squeezed together well. This rear part should be able to be epoxied into place onto the hull and transom tomorrow.

2 hours

Sanded Re-filled Holes/Fiberglassed Bottom of Rear Seat Top

2011-04-11T23:44:00.006-05:00

Today, I fiberglassed the bottom of the rear seat top and applied a second layer of epoxy as well. I also sanded down all of the re-filled areas of the holes that didn't completely fill in the first time around. The interior holes that were filled in at the front of the hull section under the front deck were also sanded down.

The transom doubler was sanded down for the next layer of epoxy.

I began to try to figure out the pilot house set up as well.

3 hours

Sanded Filled Holes/Fiberglassed Rear Seat Top/Rounded Transom Doubler

2011-04-10T20:05:00.010-05:00

Today, I sanded down all of the holes filled yesterday and then applied thickened epoxy on the ones that didn't fill all the way in. I also sanded down the interior filled holes, as well as filled the ones up below the front deck that I didn't get to before. They will be sanded down tomorrow.

I also fiberglassed the top of the rear seat after re-fitting it to the boat. The front of the rear seat was rounded over with a 1/2" roundover bit before fiberglassing, as well. I will wait for it to cure before cutting out the rear seat hinged part.

The transom doubler was rounded over with a 1/2" roundover bit on my router and then covered with a layer of epoxy.

The sides of the hull that stuck out behind the transom were sanded down to match the transom and the corners were rounded over by hand sanding.

6 hours

Screws Removed and Holes Filled

2011-04-09T17:32:00.005-05:00

Today, I removed all of the screws that held on the hull side doublers and then sanded and filled each hole (inside and outside) with a epoxy/wood flour mixture.

5 hours

Right Side Hull Doublers Epoxied On

2011-04-09T09:32:00.005-05:00

Yesterday, I epoxied on the right side hull doublers with the same method as the left earlier.

4 hours

Left Side Hull Doublers Epoxied On

2011-04-07T23:21:00.006-05:00

Tonight, I epoxied on the three left side hull doublers. I first put epoxy in every hole that was used to put the original sides one along with a cut-off toothpick to help fill the hole. I then put thickened epoxy inside of the holes to fill them up. Then I applied at least two layers of epoxy on each side of each part that were to be attached to each other, then screwed them back on.

4 hours

Both Hull Sides Now Set

2011-04-05T07:40:00.005-05:00

Yesterday, I set the last right side and all three left side additional 1/4" hull side doublers to be cold molded on today or soon.

3.5 Hours

Sanded All of the Newly Taped Areas/Began Attaching the Extra Sides

2011-04-03T22:09:00.007-05:00

Today, I sanded down all of the newly taped areas. I also began attaching the extra side doublers that will make the hull sides 1/2" instead of the 1/4" in the drawings, which should make it quite a bit stronger.

4.0 hours

Photos of the Newly Taped Areas

2011-03-31T12:01:00.002-05:00

Here are some of the photos I didn't have for the last post.

Taped All Sides to Everything Left

2011-03-29T17:53:00.002-05:00

Today, I fiberglassed all the remaining areas that the sides attached to, including the transom, bottom of the hull, rear seat verticals, top of front deck and front seat boxes. They were first filleted everywhere and then either 3" or 4 " fiberglass tape was used, depending on the area.

3.5 hours

Front Deck Installed / Bottom Taped To Sides

2011-03-28T20:37:00.008-05:00

Today, I taped the front bottom to sides with either 4" fiberglass tape or two overlapped 3" pieces of fiberglass tape.

I also installed the front deck and cleaned up all the extra epoxy.

4.5 hours

Front Deck Top Fiberglassed

2011-03-22T20:33:00.001-05:00

Today, I fiberglassed the top side of the front deck, as well as putting on the second layer of epoxy.
1 hour

Bottom of Front Deck Fiberglassed

2011-03-21T18:26:00.002-05:00

Fiberglassed the bottom of the front deck. Will add another layer of epoxy in a couple of hours.

1.5 hours

Front Deck Made and Set

2011-03-21T07:18:00.002-05:00

Yesterday, I used the template to make the front deck and fit it into place with #8 screws.

2 hours

Front Deck Template Made

2011-03-18T21:02:00.006-05:00

Today, I made the template for the front deck out of cheap luan plywood. I also laid out the lines for the pilot house.

2 hours

Hull Sides Glued and Screwed

2011-03-16T18:07:00.005-05:00

Yesterday, I spent time trimming the hull sides to the proper lines. I also got two more 1/4" pieces of plywood and drew out and cut out the second layer pieces that will go on soon.

Today, I epoxied the hull sides in to place and screwed them down with approximately 45 screws per side.

9 hours

Finished Screwing the Hull Sides On

2011-03-14T19:52:00.002-05:00

Today, I spent a couple of hours screwing the hull sides on completely. Now I will take them off and trim all of the appropriate areas.

2 hours

Aye Mates, She's A Boat!

2011-03-13T22:15:00.005-05:00

Well not quite, but today I began fitting the hull side to the bottom. She is beginning to look like a boat now anyway! I am using #8 x 1" stainless steel screws to test fit it.

2 hours

Hull Sides Ready For Installation

2011-03-12T17:22:00.003-06:00

Today, I trimmed off the excess fiberglass all along the sides and sanded down all of the fiberglassed surfaces. The sides are now ready to be fit onto the boat!

2 hours

Hull Sides Cut Out to Shape and Fiberglassed

2011-03-11T19:25:00.010-06:00

Today, I finally cut out the hull sides after laying out the lines on the plywood. I cut about 1-2" more on the front bottom so I can match it to the exact shape of the existing bottom of the boat.

I then fiberglassed, with fast hardener, the interior side of the hull sides and also put on a second layer of fast curing epoxy. If you look closely at the photo where the epoxy has already been applied, you can see what appear to be dry areas. That photo is before I added the second layer of epoxy, so they are covered pretty well now.

I have pretty much decided to cold mold a second 1/4" layer of plywood on the sides after these sides have been installed. After doing a couple of break test on the 1/4" plywood, I found it broke way to easily, from what I expected anyway. If I add a second layer, it will only add about 30 lbs. to the boat, but the sides will be so much stronger.

6 hours

Hull Side Scarfs Sanded and Faired

2011-03-07T18:03:00.006-06:00

Today, I sanded down the scarfed areas and filled knot holes and then applied another layer of epoxy and wood flour to fair the scarfed areas. I used the fast cure hardener, so I hope to be able to sand this tonight and draw out the sides, then fiberglass the interior side.

1 hour

Hull Side Scarfs Epoxied Together

2011-03-05T13:22:00.006-06:00

Today, I epoxied all of the hull side scarfs together as well as filled all of the small, and not so small, knot holes in the interior side of the hull sides. I put weights on all of the epoxied scarfs, as well as screwed them down to a 2"x6" pieces of wood. It should be enough to keep them tight.

I will wait until the epoxy cures, then fair everything, and add another layer of epoxy and wood filler along the seams to fair them and then fiberglass the interior side of them before attaching them to the boat.

2 hours

First Try at Making a Fender

2011-03-03T22:18:00.003-06:00

Tonight, I made a small fender with 3/8" manila rope. It took about two hours from start to finish. I really want to make some bigger ones with 3/4" manila rope, but I wanted to see what it would take to make them first so I started small. It ended up about 2 1/4" in diameter and 12" long including the bight.

2 hours

Transom Doubler #2 Installed; Hull Sides Cut Out and Scarfs Cut

2011-03-01T22:23:00.009-06:00

Today, the second transom doubler (or tripler) was sanded to match the shape of the installed doubler and then epoxied to the 1st doubler to make the transom 1 3/4" thick on the area that the outboard motor will attach to.

I also laid out the hull sides, cut them out, and cut the scarfs on each piece. A 2" scarf was used since it is 1/4" plywood. I am not too happy with the way there was some ripout along the edges, but I will use some thickened epoxy to fill those areas as well as some of the interior side knot holes. I hope to epoxy them up tomorrow.

4 hours

Transom Doubler #1 Installed

2011-02-28T21:14:00.005-06:00

Tonight, I cut out both transom doublers and epoxy the first one onto the transom. I will let it cure overnight and install the other one tomorrow. I used #8 screws 1 inch long to attach it to the transom curvature.

The first picture is the one that will be installed tomorrow, but I put the first layer of epoxy on the part to seal it.

2.0 hours

Front Seat Boxes Completed!!

2011-02-27T10:31:00.004-06:00

Well, that took longer than expected, but the front seat boxes are now sanded down smooth and another layer of epoxy was applied last night. A lot of other sanding on the floor was completed as well to get ready for the hull sides.

3.5 hours

Front Seat Boxes Fiberglassed

2011-02-25T11:52:00.007-06:00

Yesterday, I cut out all of the fiberglass needed for putting on the exterior of the front seat boxes.

Today, I epoxied the fiberglass on them. After they cure, I will cut out the fiberglass where the access holes are now.

2.0 hours

Front Seat Boxes Taped to Bottom

2011-02-23T15:05:00.005-06:00

So far today, I fiberglassed taped the front seat boxes to the bottom after filleting the areas. I am now beginning to layout the side pieces.

2.5 hours

Front Seat Boxes Epoxied Onto Bottom

2011-02-22T19:57:00.006-06:00

Today, I epoxied the front seat boxes down to the bottom of the boat. The right one had somewhat had the rear part move in, so I took a 2x4 and put in there to keep it spread to the right size until the epoxy cures. I will also put down fiberglass tape on the exterior to strength it up, before I remove the 2x4.

Before I epoxied them down, I took four small 3/4" stainless steel nails and put them at the back of where the seat boxes should be, so they couldn't move rearward when I put them down. These nails will be filleted over tomorrow, along with the 3" fiberglass tape. You can see the nail in the upper right photo if you look close.

2 hours

Rear Seat Top Cut; Front Seat Boxes Epoxy Layered; Bottom Epoxied Up

2011-02-21T21:49:00.007-06:00

Today, I completed the interior of the front seat boxes by adding another layer of epoxy to seal them after making sure that all taped areas were smooth.

I also cut out the rear seat top to size and planed the rear edge to match the transom, but I still haven't decided on how to cut out the hinged seat part. That problem is due to the engine I decide to use as well as if it is a long shaft or short shaft. I really want to use a long shaft, as the transom will not have to be cut down as much and I may not have to cut into the rear seat top. I will have to get the engine first before I can really decide how to do the rear seat.

I also applied another layer to the entire top of the bottom of the boat from the rear seat vertical to the front fence strengthener.

I hope to epoxy on the seat boxes to the bottom tomorrow!

6 hours

Front Seat Boxes Cont

2011-02-20T20:14:00.003-06:00

I sanded down the interior of the seat boxes where I fiberglass taped the other day as well as most other areas. I will add a layer of epoxy to finish them up before attaching them to the floor. I know that no one will see these areas when the boat is completed, but I want everything to look really good when finished, and it doesn't take a whole lot of extra time or epoxy to make it look good.
1 hour

Front Seat Boxes

2011-02-18T18:37:00.002-06:00

Two additional layers of epoxy were applied to the inside of the front seat boxes. Now waiting on them to cure so I can fiberglass the outside of the boxes and attach them to the floor.
1 hour

Sanded the Tape Work and Taped the Inside of the Front Seat Boxes

2011-02-17T15:38:00.005-06:00

Today, I sanded down the fiberglass tape work I did yesterday on the rear seat vertical and then applied a layer of epoxy over the entire vertical and between the vertical and the transom.

I also fiberglass taped the inside of the front seat boxes for additional strength, as well as epoxied the entire inside surfaces.

4 hours

Taped the Vertical Rear Seat Piece

2011-02-17T07:53:00.006-06:00

Yesterday, I filleted the front and the back side of the rear seat vertical piece and applied 3" fiberglass tape and epoxy. I also finished filling the holes in the two front seat boxes.

2 hours

Rear Seat Vertical Epoxied; Front Seat Access Holes Cut

2011-02-13T19:53:00.009-06:00

Today, after a long break for school and other projects, I cut the access holes in the front seat boxes and routed the edges with a1/2" roundover bit. I also filled most of the countersinked areas on the front seat boxes. A few more to finish it out next time.

First I sanded down both sides and then I trimmed the excess fiberglass and epoxy from the vertical rear seat piece and epoxied it into place at a 90 degree angle from the bottom. I also cleaned up each vent hole on this piece with a sanding wheel on a Dremel tool.

Rear Seat Fiberglass and Front Seat Box Doublers

2010-12-21T22:43:00.007-06:00

Today, I fiberglassed the rear seat vertical on the front side and applied a second epoxy layer after waiting about 5 hours. I also cut to size and epoxied on the doublers on the front seat boxes where I will cut the access hole.

4 hours

Rear Seat Started

2010-12-20T23:24:00.004-06:00

Tonight, I cut out the vertical part of the rear seat, and cut 1 1/2" vent holes in it as well as angled the sides to match the sides of the boat and the area around the quarter rounds.

I also took out the screws on the seat boxes so they would not set and be impossible to get out later when the epoxy fully cures.

Today 8 hours

Front Seat Boxes Epoxied Together

2010-12-20T14:39:00.005-06:00

Today, the front seat boxes were epoxied together after sanding all the edges smooth. I also marked on the front of the seat boxes where I am going to cut a hole to allow access to this area after it is put on. The hole is 6" x 12". I may move it inboard a little bit to allow for the pilot house sides. I will also double up this front piece with another 1/2" piece of plywood to strengthen it.

Stem Quarter Rounds and Seat Box

2010-12-16T10:31:00.006-06:00

The last couple of days I cut to length and epoxied on the quarter rounds to each side of the stem where the sides will attach.

I also began building the seat boxes. I haven't decided the best way to finish them as I would like for the area to be accessible for storage. I may cut a hole in the front and double up the plywood there for strength.

Fence Installed On Bottom

2010-12-08T22:54:00.007-06:00

Today and tonight I installed the fence. I first cut it to size and to match the quarter round pieces on each side, and I rounded over the top with my router. Then it was epoxied to the bottom.

After it cured enough, I put fiberglass over the entire piece and also put 3" fiberglass tape on each side, fore and aft.

4 hours

Quarter Rounds Epoxied To The Bottom

2010-12-08T09:35:00.008-06:00

Yesterday, I epoxied and nailed the quarter rounds for the sides down to the bottom of the boat. They didn't want to go down straight, but they are pretty close and can be sanded to match the sides exactly.

1.5 hours

Quarter Rounds For The Sides; Transom Trimmed

2010-12-06T10:09:00.005-06:00

Yesterday, I made the quarter round pieces (4 in all) that will attach to the bottom and the sides. They were cut to length, cut with a band saw every 1 inch or so to allow them to bend easier, drilled with a #54 drill bit approximately every four inches, and the appropriate length nail was put in each hole. Next they will be epoxied down to the bottom.

I also trimmed the transom sides to match up with the sides of the boat when they are installed, and sanded and smoothed down the transom to bottom joints fore and aft.

5 hours

Made a Small Parts Paint Booth Today!

2010-12-04T18:16:00.004-06:00

Today I decided to make a small parts paint booth that will have a squirrel cage fan and vent to the outside of my garage through a dryer type vent.

It took me three hours to get to the stage in the photos. I still have to buy a blower (squirrel cage fan) and make some type of fiberglass vent system that will hook to the back of the paint booth, go through the fan and into the dryer vent.

Taped The Transom

2010-12-01T14:14:00.008-06:00

Today, I nailed down the quarter round strip on the forward side of the transom to the planing doubler after applying non-filled epoxy and then a epoxy/wood flour mix. I then filleted the part to mess nicely with the transom and bottom of the boat. I also used the epoxy/wood flour mix to fillet the aft side. Then I fiberglassed taped the transom with 4" tape on the forward and aft sides and filled with epoxy. I have also waited about two hours and applied another layer of epoxy to fill the weave. One or two more layers of epoxy should take care of that.

4.5 hours

Did You Miss Me? Lots of Work Done!

2010-11-29T13:06:00.015-06:00

Well, it has been a very long time since the last post, but I actually have been getting things done! Not as much as I would have like to, but I am also completing the RV-9A airplane for my buddy Pat! Huge job there! Finally got it completely wired up and ready for paint! Close anyway.

The front part of the planing doublers were added, and I have rounded off the corners on the top side and bottom side of the area of the planing doublers and fiberglassed the planing doublers on the top side. There was also fiberglass installed in between the layers, which was actually part of the top side of the bottom of the boat. I am also going to install another layer of fiberglass tape around the entire sides of the planing doublers to add strength and water resistance. They will be the parts to contact the dock or whatever while in the lake, so they need to be reinforced as much as possible.

I have also angled the bottom of the transom exactly 12 degrees with an electric planer and a hand planer to allow it to angle 12 degrees aft when installed, fiberglassed the transom on both sides, and finally installed the transom on the planing doubler yesterday. I used blocks screwed to the planing surface on the forward and aft sides of the transom to hold it exactly in place, and they had the added benefit to hold it up as well, which I did not expect. I was going to build a jig to hold the top side, but didn't need to. BUT, I did have to stand there for almost three hours yesterday pushing down on the transom after the epoxy was applied, because I could see it not mating properly if I let it go. That was REAL fun, let me tell ya! At least I could watch the TV while I held it in place. I need to put fiberglass tape and epoxy on the bottom now to secure it totally in place. I don't think it will break free, but I definitely want to make sure it doesn't happen. I will also install the quarter round pieces next. The transom is not to the final shape it will be, as I will install the sides first AND decide on a long shaft or short shaft motor to put on it, which will determine it final shape.

All together approximately 20 hours, including all the sanding, etc.

Keel Taped to Bottom

2010-08-29T13:22:00.007-05:00

Today I sanded down all of the areas where the keel meets the bottom and then fiberglass taped them with epoxy. I first filleted the corner areas with epoxy/wood flour mixture and rounded it out nicely.

I also added a layer of epoxy to the bottom in the areas that will not be taped to the sides. I left them sanded down, because there will be a little ledge of epoxy next to it when they are taped.

3 hours

Planing Doublers Epoxied To Bottom

2010-08-23T21:29:00.008-05:00

Today, I epoxied the planing doublers to the bottom and clamped it down as well as adding weights on the areas I couldn't clamp. You never can have enough clamps!This doubler will make the back portion of the bottom 1". I also clamped a straight piece of 2x6 on the back of the planing surfaces to hopefully get them straight in-line with each other once they have cured.

I also semi-installed the U-bolt on the stem. I have to drill 1/2" holes for it to go through, and I started to installed it then take it back out, but it was getting damaged trying to get it back out. So, I will just add some epoxy to the threads later and push it all the way in and tighten the bolts. After I received this U-bolt, I thought it was way too big and I probably should have got the 3/8" version, but I couldn't find one long enough to go all the way through the stem. Oh well, it is installed now! Maybe I should have looked harder!

4 hours

Lots of Stuff!

2010-08-22T19:51:00.008-05:00

Today and yesterday, I sanded down the entire top side of the bottom, making it nice and smooth, especially where the fiberglass overlapped.

I also trial fit the transom to the bottom and marked its location and where it will need to be cut to match the sides. I then marked out where the planing doublers will be on the bottom. Taking those measurements, I marked out the planing doublers on 1/2" plywood and cut them out.

I also smoothed out all of the epoxy/wood flour filled holes on the transom.

6 hours (1 hour last night and 5 today)

Seat Design Chosen

2010-08-21T17:37:00.003-05:00

I have chose this design for my seats in the white/red/charcoal colors. Should be comfy!!

Top of Bottom Now Fiberglassed

2010-08-19T21:04:00.005-05:00

Tonight, I filled the holes for the fasteners that went through the bottom to the keel. Then, I added a layer of fiberglass to the top of the bottom. I also put an extra layer of epoxy on top after the initial layer.

3 hours

Bottom Attached to Keel

2010-08-17T19:56:00.006-05:00

The bottom was epoxied to the keel with the first layer of un-thickened epoxy and then a layer of epoxy/wood flour on the entire surface of the keel that attached to the bottom. I used wood screws and washers to tighten everything down. A little weight was used in a couple of areas to help it contour to the keel better.

After this dries, I will be filling all of the holes with a epoxy/wood flour mixture and then fiberglass the entire top side of the bottom. Then I can install the seats, fence, etc.

2 hours

Keel Taped

2010-08-16T07:28:00.006-05:00

I decided to tape the keel on the inside corners for extra strength before attaching the bottom. This was the last chance to strengthen anything in the keel, as it will be completely closed off after attaching the bottom. I sanded down the epoxy in the corner areas so the new epoxy and fiberglass tape would adhere good.

I also put a layer of epoxy on all surfaces that will attach to the bottom to seal them.

3.5 hours

Trial Fit the Bottom to the Keel

2010-08-12T22:56:00.007-05:00

The bottom was fit to the keel and marked for the fasteners that will go through the bottom into the keel stiffeners. The bottom was then taken off, marked, and drilled. Then, the bottom was put back into place on the keel and the fasteners were installed to hold the bottom down tight for the epoxy/wood filler that will be next.

The sides of the keel were sanded enough to take the layer of tape that will be applied once the bottom is epoxied to the keel. I also made sure that the keel stiffeners are level so the bottom will sit up tight against as much of it as possible.

4.25 hours

Bottom Sanded Smooth

2010-08-11T22:11:00.007-05:00

Early this morning (about 5:00 AM), I put on two more layers of epoxy to fill the fiberglass weave. This had time to cure while I was at work today with the extremely hot temperatures Wichita has been experiencing.

Tonight, I cut the edges of the fiberglass off and sanded the sides smooth. I also sanded down the entire fiberglassed area with 40 grit sandpaper disc on my electric 5" disc sander. You can tell it has been sanded enough with there is no shine left on the epoxy (cloudy appearance), as well as taking down any rough spots. You can also see where the two pieces of fiberglass came together, which is now sanded down to be as smooth as possible. I believe some of that area will be under the keel when finished. By the time it is complete there will be a few more layers of epoxy on all surfaces.

Next will be to attach this bottom to the keel.

3 hours