If you’ve ever used Pinterest, then you know that it is filled with projects that give a false sense of confidence in your own artistic abilities. Hence, the wildly entertaining “Pinterest fails”. Mindlessly scrolling one day, when I probably should have been doing something productive, I stumbled across a rustic wood wall art piece. A little epoxy, some scrap wood, and I can build that. No problem.
A very high percentage of boats in the U.S. are at least 30 years old. It doesn’t surprise me when a boat’s plywood components fail due to water intrusion. In my experience, the transom is the first area to rot out in most trailerable boats. That’s not to say the first thing to rot couldn’t be the cockpit floor, stringers, or motor mounts. Continue reading →
Let’s look at a good method for building curved walls curved-face cabinets. A while back, as I was waiting in the reception lobby of a major American corporation, I had the chance to admire the curved reception desk and other oak furniture in the room. However, when I examined the reception desk more closely, I could see facets in the oak veneer instead of a nice, smooth curve. I immediately realized that the cabinet builders had sawn closely spaced saw kerfs in the back of the panel so they could bend it to shape. I thought there must be a better way. Continue reading →
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 →
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 →
Above: Jeff Wright, Vice President of GBI Technical Services, poised to take a deep dive into types, materials, costs, weight, and stiffness of flat panels.
Many WEST SYSTEM® customers appreciate the benefits of cored composite construction. They understand that it creates a part that is lightweight, strong, and stiff. We often receive calls from these customers inquiring about using a composite panel when building or repairing something that would normally be made of plywood. Such projects may include a new center console for a fishing boat or the replacement of flying bridge side shields. Determining the best material requires consideration of many aspects of the project, but often comes down to cost versus weight. Continue reading →
Above: Shown upside down, the base of Jon Staudacher’s trailer is a series of plywood torsion boxes, doubling as storage compartments. The depth of the boxes makes a very lightweight, rigid structure.
Over the years, we have featured some of Jon Staudacher’s more innovative projects and ideas. From his extreme house, to race boats, to aerobatic airplanes, to a gate at the end of his driveway, to something as simple as a paint roller brake, Jon has always sought the simplest method to build his projects. Jon’s latest project is no exception.
Above: Marine-grade plywood basics include knowing how to select marine-grade plywood for flexibility vs. stiffness. This wing mast required plywood with some flexibility.
Since so many projects in Epoxyworks incorporate plywood, we felt it might be valuable to discuss briefly the types of marine-grade plywood and some construction methods best suited to it. It’s easy to understand why people like plywood and choose it for so many projects: it is readily available, comes in convenient sheets (typically 4’×8′), is pretty light for its stiffness and strength (1/8″ plywood weighs about 11 lb per 32 sq ft panel), and is a bargain when compared to the price of many composite panels. Continue reading →
Thomas Heavner of Seattle Washington designed and built his own 18′ plywood runabout. Mr. Heavner sent pictures of his project and wrote, “This is the first boat of any kind that I have designed and constructed. Your book (The Gougeon Brothers on Boat Construction) made it possible to build this boat.
The Society of Automotive Engineers (SAE) asked Composite Concepts, Inc. to build a three dimensional version of the SAE logo for the SAE International Congress Banquet in Detroit, Michigan. An easy feat, until you consider the size of the letters. They are 22′ tall, 56′ wide and 4′ deep, with a horizontal 2′ high split down the middle. Add some projection and neon lighting, and you have an impressive back drop for the engineers receiving their awards at this black tie dinner. The speakers entered the stage from under the letter A before they approached the lectern. Continue reading →