I used lost foam construction to fabricate a fiberglass air scoop for my son’s Formula Continental C race car. Our project started because a modification to the shape of the race car body necessitated the construction of a new air scoop. The air scoop is bolted to the car body so if either the air scoop or the body is damaged (a very likely scenario), the repair will be simpler. To fabricate the scoop, I made a Styrofoam male mold, surrounded the mold with fiberglass, and then dissolved the Styrofoam to leave a hollow part. I used Styrofoam to build the male mold for several reasons. It is readily available at most lumberyards, it is easy to shape with files and sandpaper, and it is easy to dissolve with lacquer thinner.
Creating a masthead fitting is another use of the lost foam method to produce a custom part with a molded interior cavity. In this case, the part was a masthead fitting to hold an internal sheave and provide a route for the halyard to pass. This method can be adapted to a variety of other applications, as demonstrated in Fabricating an Air Scoop.
Cover Photo: Greg Hatten battles white water on a trip through the Grand Canyon in his replica wooden dory, PORTOLA.
On March 21, 2012, river runners from five western states, Canada, Japan and Chile launched five homemade wooden dories, replicas of important historical designs, in an attempt to complete a 24-day self-guided traverse of the Colorado River through Grand Canyon. The replica boats represented a snapshot of river running in Grand Canyon during the 1950s and 1960s, just before Glen Canyon Dam took control of the Colorado River through Grand Canyon. Continue reading →
Sealing and priming a surface prior to applying the final finish affects how it ages, and how it ages has everything to do with the way the finish is anchored to the wood. Sealers and primers are often taken for granted; we simply read the can and follow directions. There are so many reasons for using a sealer and many methods for applying them. Let’s look at what we learned while sealing Sparks, the electric launch I built. Continue reading →
A grapnel or grappling hook is a device with curved tines or “flukes” attached to a rope used for retrieving overboard objects. For pleasure boaters, a grapnel should be small, lightweight, and made of non-rusting materials. I think every cruising boat should have one. The only ones I could find were too large or were a folding grapnel anchor, not a retrieving hook. Continue reading →
Ten years ago the rear fender on my son John’s 1991 Honda Accord was damaged just forward of the wheel. It had been repaired at a local body shop, but four months later the same fender was rusting. I took it back to the body shop. The manager apologized and agreed to redo the job, but said there wasn’t much metal for his technicians to work with because the car had rusted significantly prior to the accident. He couldn’t guarantee that it wouldn’t rust again. Continue reading →
Are you the kind of person who just can’t get enough of a good thing? Looking for a better way to squeeze out that last little bit of G/flex 655 Thickened Epoxy Adhesive from your tube rather than resorting to pliers, a vise, or maybe even Grandma’s rolling pin? Maybe you’d like to get a fatter bead of adhesive or your tube is a bit clogged. Boy, do we have some easy and inexpensive tricks for you! Continue reading →
While WEST SYSTEM® epoxy has a long shelf life, age will eventually affect its handling characteristics and cured strength. When stored for very long periods, hardeners may turn darker (reddish to purple), become thicker and give off more odor. 105 Resin may lose some clarity and also become slightly thicker. Use extra care when mixing age-thickened products (stir extra thoroughly), and if color and/or clarity are crucial to your project, buy some fresh resin and hardener for best results. 207 Special Clear Hardener is specially formulated for clarity and flow. Continue reading →
I could envision my two young daughters rowing a skiff boat their dad built, but I had to convince my wife. I like to fish and so do my girls, so a good fishing skiff couldn’t hurt. “Think of all the fish fries,” I told my skeptical wife. When I told my brother that I was going to build a boat he asked me, “Why?” I didn’t discover the answer until after the project was completed. Continue reading →
By Glenn House — Director of Product Safety and Regulatory Compliance
Over the course of the last couple of years, Gougeon Brothers Inc. has partnered with Waste Management Inc. to implement a comprehensive recycling program that has been both simple and effective. We are now recycling emptied plastic and metal epoxy containers, shrink wrap from bulk packaged items, dispensed adhesive cartridges, cardboard boxes, miscellaneous soft and rigid plastic items, office paper, magazines, etc. Continue reading →