Author Archives: ewadmin

Recycling & Disposing

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

Epoxy Compression Test in Progress

Testing Epoxy to Determine Physical Properties

by Mike Barnard

In this article, I’ll describe our standards for testing epoxy and how we go about testing epoxy to determine its handling characteristics and cured physical properties.

Epoxy Testing Standards

These are the standards we follow no matter which epoxy we are characterizing.

Two-week room temperature cure

After proper metering and thorough mixing epoxy will continue to cure after it has solidified until all amines have paired up. Over years of testing epoxy, we have found that two weeks of curing at room temperature, which we define as 72°F (22°C), is a good indication of its full strength. Continue reading

Jester's cabin sole gets repaired

Repairing JESTER’s Cabin Sole

Who’s Laughing Now?

By Greg Horvath as told to Bruce Niederer

The following photos detail some recent cabin sole repairs made by the owner and crew of Jester, a 2005 C&C 99. Jester is well equipped and has been meticulously maintained by her skipper and only owner, Greg Horvath. Jester has only sailed in fresh water and is stored indoors during the winter. She is also the boat I’ve raced aboard here in Saginaw Bay as well as around the Great Lakes including the Port Huron to Mackinaw Race and the Ugotta Regatta in Harbor Springs. Continue reading

White oak samples for testing

Letters to the Editor – White Oak

By Bruce Niederer — GBI Technical Advisor

My article, White Oak Redux (Epoxyworks 34), generated two responses we wanted to share. We consider ourselves students as well as tech advisors and so we’re always open to learning something from others. Our readers are generally pretty savvy people, and when they take the time to write us a thoughtful letter, we feel compelled to share what we learn from them with the rest of our readers. Continue reading

Stray Cat Strut

Restoring a Gougeon Tornado Catamaran

By Andy Davidson

I have just about finished restoring a Gougeon Tornado catamaran. I’ve always had and loved catamarans, and this one had been sitting out in the sun at the Oklahoma City Boat Club for years. Bob, a fellow club member, offered some parts. His plans were to “chainsaw the hulls tomorrow” and put the pieces in the club Dumpster. That was the push I needed. In a moment of insanity, I told him there was no way I could let him do that. Continue reading

The base relief sculpture Creation of Life by Kirk Williams

A Base Relief Sculpture in the Modern Bronze Age

By Kirk Williams

In 2010, I was given a commission to do a base relief sculpture for the Pioneer Care Center, a new retirement home in Fergus Falls, Minnesota. The sculpture, called “Creation of Life” was to be mounted on a wall about 14′ off the floor. I knew I had to make it strong and lightweight. The method I used was to sculpt the design in oil based-clay on a large wooden easel. Then I covered the finished clay sculpture with several layers of clear silicone, occasionally adding cheesecloth for build-up and strength. When the silicone was thick enough, I built a mold cradle, made of plaster and gauze reinforced with heavy metal wire over the silicone. When the mold cradle had dried, I removed it and the silicone mold and laid them flat.

1.) Williams first created the base relief sculpture in clay on a wooden easel.

1.) Williams first created the base relief sculpture in clay on a wooden easel.

2.) Epoxy/bronze mixture was buttered into the silicone/plaster mold.

2.) Epoxy/bronze mixture was buttered into the silicone/plaster mold.

3.) The silicone mold was peeled from the base relief sculpture.

3.) The silicone mold was peeled from the base relief sculpture.

4.) Buffing the sculpture with steel wool exposed the bronze powder.

4.) Buffing the scuplture with steel wool exposed the bronze powder.

I made a mixture of 105/205 epoxy and added bronze powder until it was the consistency of chocolate frosting. 105/205 gives me enough time to mix and spread it into the mold, but sets up within about an hour, making it possible to start another application. The epoxy/bronze mixture was buttered into the mold by using two fingers (gloved) to an eggshell thin layer, to avoid any possibility of air bubbles. When this cured I built up reinforcement layers using epoxy mixed with chopped fiberglass and Christmas tree flocking. For additional reinforcing, I embedded heavy wire and small iron rods.

After the final epoxy application had cured, I attached the base relief sculpture to a wooden frame with wires embedded in the back of the sculpture. With the frame standing vertically I gently pulled the silicone mold from the sculpture. I trimmed the rough edges with a Dremel® tool. Buffing the surface with steel wool brought out the metal, and gave me control over the amount of contrast. Olive oil rubbed over the surface gave the sculpture a smooth patina.

The 8′ long sculpture weighs less than 150 lb and was lifted using a scissor lift and hung 14′ above the floor level with ease.

5. The completed base relief sculpture weighed only 150 lb and hangs 14' above the Care Center floor.

5. The completed base relief sculpture weighed only 150 lb and hangs 14′ above the Care Center floor.

Architectural columns built by Pleasant Bay Columns

Pleasant Bay Columns

By Suzanne Leahy
Epoxyworks 34

Cover Photo: The finished 24′ front columns built by Pleasant Bay Boat & Spar Company.

In 2006, I was contacted by a wood consultant whose client was looking for a shop to turn solid Ipe architectural columns. He’d found out about our company through the Federal Reserve project. STA Architectural Group was the principal designer of a private residence under construction in South Florida. Their trademark motif was tropical hardwood architectural columns resembling palm trunks. This design called for unusual dimensions for eight columns.
Continue reading

Building a Custom Stained Glass Lampshade Mold

With G/5 Five-Minute Epoxy Adhesive

By Tom Pawlak — GBI Technical Advisor

A few years back Mary, my better half, suggested I make a custom stained glass lampshade for our den at home. There are molds commercially available for making glass lampshades. They hold glass pieces in position in the desired curved shape until the soldering process is complete. Unfortunately, the shape I wanted was not available. I wanted something similar in size and shape to the fabric-covered lamp shade in the den. In the end, I decided to make a custom mold. Continue reading

SPARKS by Ted Moores

Skeg Construction for SPARKS

Lesson 3 in our series on Strip Planking

by Ted Moores

Designing and constructing a successful skeg for Sparks (our 30′ hybrid electric launch featured in Epoxyworks 32) took some head-scratching. But in the end, it was just another combination of wood and WEST SYSTEM® epoxy. Our skeg needed to be functional and age gracefully, yet be reasonably quick and easy to build and install. This project was an ideal opportunity to explore the limits as well as the advantages of combining wood with epoxy to engineer simple solutions to complex problems. Continue reading

Mike's fancy epoxy caddie

The Coupe de Ville of Epoxy Caddies

By Mike Barnard

Inspired by an old Boatbuilder article by Captain James R. Watson, my father and I built our own deluxe epoxy caddy, which we call the Coupe de Ville of Epoxy Caddies. My dad has grown very fond of WEST SYSTEM® Epoxy and his box of epoxy-related items has been growing at a steady rate. The overflow of his box in an already “treasure” packed garage emphasized his need for an organization and storage system for these materials. We have had several requests for this same type of solution lately. Continue reading