Category Archives: Composite Fabrication

Boyscout Klondike Derby sled.

Boy Scout Composite Klondike Derby Sled

by Tom Dragone, PhD

About the Klondike Derby

The Klondike Derby is an annual winter camping trip held in our district (and many others across the country) for Scouts to hone their scouting skills in a winter environment. During the weekend event, Scout patrols go from station to station around our local Scout Camp, facing challenges that require them to demonstrate their skills in making a fire, navigating with a map and compass, cooking, knot-tying, and applying first aid. The Scouts must bring all their gear with them as they trek from station to station, including ropes, stoves, kindling, and hiking staves. Hence, each patrol is required to have a sled for their gear which they, as a patrol, must haul. The sled must be strong and stiff to hold the patrol gear, yet lightweight because at the end of the weekend there is a race between patrols, and the fastest sled wins.

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G-32 catamaran G-WIZ!

G-Wiz!

Russell Brown’s New Toy

By Russell Brown
G-32 catamaran on the cover of Epoxyworks 46, Spring 2018

Russell Brown’s G-32 catamaran on the cover of Epoxyworks 46, Spring 2018

The work of the Gougeon brothers has been like a guiding light to me starting when I was a young teenager. It wasn’t just the methods and skills they developed that inspired me (and led to my career in boatbuilding), it was the “outside the box” thinking about boat design they employed. While Meade Gougeon led the effort to develop and teach epoxy skills and building methods, it was his brother Jan who had the courage to design, build, develop, and race boats that were very unusual and often counter-intuitive, yet very successful. Jan’s G-32 catamaran is an example of his genius. Continue reading

penguin mailbox epoxy

A Penguin in Iowa?

By Ryan Krafka

I first got the idea for this project driving through a neighborhood in Iowa City where my wife and I live and work. “You have to see this awesome mailbox,” I said to my wife as we drove through a neighborhood one day this past fall. There it was, a dolphin mailbox. Not just a mailbox with dolphins painted on it, but an honest to nature fiberglass dolphin with fins holding a mailbox beneath its head. Continue reading

Lagoon by The Wright Edge

Readers’ Projects, Issue 46

The Wright Edge

Doc Wright is the owner/craftsman of The Wright Edge, an artisan woodworking business in Dallas, Texas. From start to finish, each piece is handled only by Doc or his business partner including sourcing/cutting down, milling, and drying. He uses locally sourced, 100% regionally native wood. Continue reading

Mike Barnard

Michael A. Barnard

1987—2017

The family of Employee Owners at Gougeon Brothers Incorporated lost Technical Advisor Mike Barnard, who passed away on 7/28/17. Our customers who had the opportunity to work with Mike will know that we lost an incredibly friendly, educated, and patient young man. I had the wonderful opportunity to be Mike’s manager for over 6 years, and hoped to keep him challenged until I retired. But fate took our favorite Eagle Scout well before we should have had to say goodbye. Continue reading

Stayin’ Awake at Daryl’s House

Build an insulated coffee box for when you need a lot of hot beverages

By Bruce Niederer

To stay awake at Daryl’s house requires a lot of caffeine—it must if the box o’ coffee idea he came up with is any indication. Epoxyworks readers may recall his riveting article in issue 40 Dirt Bike Loading Ramp. Daryl is talented, imaginative and loves to build stuff with carbon fiber.

The inspiration hits

Inspiration hit him one day after buying a box o’ coffee (Tim’s Take 12™) from Tim Horton’s® on his way to teach a motorcycle safety class to aspiring scootertrash. Disappointed that the Tim Horton’s boxed coffee didn’t stay warm for as long as he would have liked, he salvaged the Mylar® bag with its built-in cap and built his own insulated coffee box. Continue reading

Self Defense Canes

Wood-Epoxy Canes Do Double Duty

By Mark Copeland

Her’es how I got into building self-defense canes: After working for many years as a master plumber, followed by many more at Automotive Concept Studios where I fashioned conceptual car models from clay, I ended up with arthritis and two hip replacements. All the heavy work had caught up with me, leaving me disabled and dependent on a cane. I decided to leave Michigan during the winter months and move to Zephyrhills, Florida. I settled in and started looking for an activity to do, maybe metal detecting, fishing or golf.

Downtown, I happened by a martial arts school and stopped in to watch a class. Afterward, the owner (Master Gary Hernández) and one of the instructors (Ms. Karuna) introduced themselves to me. Both have 4th-degree black belts. I explained my health issues: limited mobility and the need to use a cane. They outlined a class Master Hernández teaches in Cane-Fu®, which is specifically beneficial to someone in my situation. Continue reading

Darth Vader cosplay helmet made with epoxy

You Can Build It With Fiberglass

Cosplay Glass’s Fabricated Helmets and Props

By Clayton Woods

Using WEST SYSTEM Epoxy Resin and fiberglass products, I have created numerous helmets, props, and pieces of armor for costuming and cosplay. Cosplay means to dress up as a character from a book, movie, or video game. Employing unorthodox and oft times experimental methods, I have kept costs low and my creativity heightened.

Just about anything you dream up can be built with fiberglass. The only real challenge is to get a close initial shape. After that, you can add or remove material with relative ease. As it is impossible to hang fiberglass in the air, you just need something to put those initial layers on. Continue reading

Merit Badge

By Tom Dragone, PhD

In Epoxyworks #38, we published an article featuring two projects that met the requirements for the Boy Scout’s Composite Merit Badge. Here, Tom Dragone tells us about two more projects completed by scouts in Troop 7369 from Chantilly, Virginia.

In 2006, the Boy Scouts of America created the Composite Materials merit badge for scouts to earn, to help them learn about the importance of composite materials and encourage them to consider careers in this field. Being an aerospace composites engineer as well as an active scouting advisor, I saw this as a natural opportunity to share my interest and experience in composite materials with the scouts in my troop. I developed a set of projects to help the scouts learn about composite materials and share them in the hope of getting more young men interested in this exciting field. Continue reading

Strings’ Float

By Greg Bull

When Jan Gougeon built Strings in 2010 one of the most interesting features he included, at least from my point of view, was the float that goes on top of the mast. Due to its zeppelin-like shape, this is also called a blimp or a dirigible. The purpose of the float is to make the boat self-rescuing: if the boat tips, the float prevents it from going any farther than lying on its side. The mast and float are then used to right the boat. Jan developed this system when designing the Gougeon-32 back in the late ’80s, so he thought it would work for Strings. Continue reading