Wooden Boat Restoration Repair - WEST SYSTEM Epoxy

4.1.1 Laminating in a jig
springback in the curved frame. Using more, thinner strips results in a curved frame
with greater strength and less springback, but requires more labor and epoxy to build.
Use thinner strips especially with harder woods like white oak.
3. Use full-length strips. Make the strips longer than the finished frame to allow for
trimming.
4. The new frame width should be the same as the original frame. Strips can be wider to
allow for trimming and finishing after the frame is laid up.
5. Select wood strips that are seasoned. Ideal moisture content is 6% to 14%.
A laminating jig will allow you to laminate a new frame in the controlled environment
of your shop. Use cardboard or other convenient material to pattern the top or bottom
line of the damaged frame. Transfer the pattern line to a laminating jig of one the types
illustrated (Figure 4-1).
Laminate frames in a jig as follows:
1. Prepare the jig and the strips as suggested. Go through a dry run to be sure the strips
bend enough and that your jig and clamps can handle the bending of all of the strips.
Cover the jig with plastic to prevent the frame from bonding to the jig.
2. Wet out the strips on both sides with epoxy, except for the outer faces of the top and
bottom strip.
Figure 4-1 Transfer the desired frame shape to the jig.
Repairing the Structural Framework 18
3. Apply thickened epoxy to one side of each strip and stack it in place on the jig against
the previously coated strip. Thicken the mixture with 406 Filler to a catsup
consistency. Be sure one side coated with thickened epoxy faces each joint.
4. Clamp the strips to the jig until the epoxy cures (Figure 4-2). Use clamps, wedges,
staples or small nails to apply enough pressure to squeeze a small amount of epoxy
from each joint.
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