Monthly Archives: November 2014

Wood/Epoxy Sump Cover

Richard Jobe was faced with having a sump located in the middle of a prominent landscaped area in front of his Newburgh, Indiana home. His solution was to build a cover (middle) for the sump that would be light enough for one person to handle, strong enough to hold the weight of half a foot of pea stone, and water resistant enough to survive being buried underground. Continue reading

Emergency Pump Repair

Barry Bew, a sailing instructor at Arethusa Venture Centre, Gravesend, Kent, UK, used his experience as a plant engineer to make an emergency repair to a swimming pool circulating pump. The pump was leaking at joints between the 3″ ABS plastic inlet and discharge pipes and the cast iron pump body. Continue reading

Installing a Bow Thruster

Island Heights, New Jersey architect, John B. Wilson, installed a bow thruster in his 26′ Albermarle sport fisherman, using WEST SYSTEM® products. The toughest part of the job was cutting through the 1″ solid hull laminate. After trying several tools, he had success with a Roto Zip™ with a ½” carbide bit by making two ½” deep passes. The only other difficult job was cutting away a portion of the floor in the storage area under the V-berth to make room for the 5″ diameter thrust tube. Continue reading

Building Alligator

BY BOB WALTERS

About ten years ago my wife, Ching, and I decided we wanted a comfortable, easy-to-handle, cruising boat suitable for exploring the shallow coastal areas that we missed when we lived aboard our deep draft sailboat twenty-one years ago. We looked at a lot of boats and decided that we would try a powerboat this time. We liked the features found on Biloxi Luggers, also known as “Chandeleur Boats,” a type indigenous to the upper Gulf Coast; however, we didn’t want to own a 30-50 year old wooden boat. Luggers aren’t available as production boats and we couldn’t afford to commission a custom design, so we decided to build Alligator ourselves. Continue reading

Testing DCPD Blend Laminates

By Tom Pawlak

Gougeon Brothers recently did R&D testing for a manufacturer who wanted to know if WEST SYSTEM® epoxy could effectively repair injection-molded parts made with fiberglass and dicyclopentadiene (DCPD) blended polyester resin that included an internal mold release. The hoods and decks for many jet skis and snowmobiles are made with this material.

DCPD blends in polyester cause it to cure rapidly and cross-link thoroughly. This feature helps to reduce emissions from the resin but makes it difficult to repair Continue reading

Replacing Damaged Bulkheads

By Dan Witucki

The port bulkhead with the chainplate still attached.

If you race a sailboat long and hard enough, it eventually will reveal its weaknesses, sometimes violently. My friends and I race an Evelyn 32-2 called Rush. Less than a month before the 2002 Mackinaw races, we were competing in the Saginaw Bay Yacht Racing Association, Gravelly Shoals race. Throughout the race the wind had been building and we were a little overpowered with a full main and 150% head sail. We had completed about 45 miles of the 50-mile race when the starboard chainplate decided it had enough and pulled out of the bulkhead. Continue reading

G/5 Adhesive Tips

By Tom Pawlak

Many of us at Gougeon Brothers experiment with WEST SYSTEM® products on personal projects at home as well as at work. We often push products and techniques beyond the limits recommended in our literature. Sometimes the experiment fails, sometimes we discover something very useful. Continue reading

Old Lady Survives 70 MPH Blast

By Meade Gougeon

The 35′ trimaran Adagio, designed and built by Meade and Jan Gougeon in 1969, survived the harrowing conditions at the finish of the 2002 Chicago to Mackinac race this past year.

The old lady
Adagio, the first large wood/epoxy structure ever built without the use of fasteners, was one of the oldest, and lightest boats in the race. She has now become a test bed as to how long wood/epoxy structures can last. Over the years, the Gougeon Brothers’ test lab has Continue reading

Repairing an Historic Statue

By Mike Barker

For over fifty years, “Sparty” has been a familiar figure on the campus of Michigan State University in East Lansing, Michigan. The Spartan statue was built in 1945 and, at 11′ tall and 3000 lb, it is believed to be the world’s largest freestanding ceramic sculpture. Sparty has survived many an attack by vandals, but it is no match for Michigan winters. Continue reading

Pacific Class sailboats

Readers’ Projects, Issue 20

Restoration of Pacific Class sailboats

These 31-10 Pacific Class sailboats appeared in Epoxyworks in 18, Fall 2001. They were being rescued and restored by a dedicated group in San Diego, California. John Sutphen, who was involved in the project, sent the photo (below) of one of the restored Pacific Class boats under sail: the reward of hard work and dedication.

Continue reading