The Gougeon Brothers on Boat Construction - WEST SYSTEM Epoxy

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viii Table of Content Later Production Steps Chapter 26 Interior Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Objectives for Interior Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317 Installing Interiors in Set-ups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 Installing Interiors in Upside-Down Hulls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318 Installing Interiors in Upright Hulls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319 General Approach--Joinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322 Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322 Making Templates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322 Bulkheads and Partitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324 Cabin Sole (Floor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325 Icebox Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326 Tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327 Windows and Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330 Electrical and Plumbing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332 Interior Final Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332 Painting and Varnishing Interiors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334 Chapter 27 Deck Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337 Preparing the Hull for Deck Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 Fairing the Sheer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338 Developing Deck Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339 Deck Framework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 Longitudinal Deck Beam Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340 Laminated Deck Beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343 Cockpit Construction and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343 Decking Over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 Sandwich-Construction Decks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346 Blocking for Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348 Cabin Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349 Deck Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350 Teak Veneer Deck System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351 Appendix A Review of Basic Techniques for Using WEST SYSTEM ® Epoxy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .357 Appendix B Wood Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374 Appendix C Fatigue Aspects of Epoxies and Wood/Epoxy Composites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379 Appendix D Scantlings for Well-Known Boats Built with WEST SYSTEM ® Epoxy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392 Appendix E Impact Testing on Reinforced Laminates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394 Appendix F English to Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396 Selected Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .397 Photo Gallery Thirty-Five Years of Boat Construction with Wood and West System ® Epoxy . . . . . . . . . . . . . . . . . follows 162
Preface <strong>The</strong> <strong>Gougeon</strong> <strong>Brothers</strong> on Boat Construction: Wood and WEST SYSTEM ® Epoxy was first published in 1979. As originally conceived, the book was an introduction to the techniques of “modern” wooden boatbuilding popular from 1960-1980. Its focus, as its title suggests, was how to mate wood with epoxy to form a composite that has physical characteristics superior to either component by itself and is stabilized from the effects of moisture. This development of wood/epoxy composites revolutionized the use of wood as an engineering material. <strong>The</strong> original book was well received, and we updated it in 1982 and 1985 to reflect changes in materials and techniques. It has continued to sell well and has introduced thousands to wood/epoxy construction techniques. It has also been used by marine trade schools and apprentice programs as part of their curriculum. In short, <strong>The</strong> <strong>Gougeon</strong> <strong>Brothers</strong> on Boat Construction has become a respected member of the canon of boatbuilding books. Much has changed since 1985 as modern wooden boatbuilding has evolved. Several of the methods we discussed, such as variations on strip planking and hard-chine construction, have become more popular. Others, such as the mold and stringer-frame methods, are now used infrequently except for molds and prototypes. In 2005, aerospace composites are in common use. Hybrids using wood and advanced composites, including aramid, S-glass, and carbon fiber, are being explored. So too are the uses of non-traditional wood species. Such uses are possible because of the ability of epoxy resins to protect and bond wood and overcome traditional durability concerns. In short, the choices for the wooden boatbuilder and customer in the early 21st century have grown immensely. Nonetheless, the techniques described in <strong>The</strong> <strong>Gougeon</strong> <strong>Brothers</strong> on Boat Construction have stood the test of time. In a simple and straightforward narrative, we describe how anyone with a few tools, some wood, and some WEST SYSTEM ® epoxy can turn out a good, safe boat. In addition, we give experienced builders a base of information from which to produce increasingly sophisticated hulls and other structures. For the student, builder, or customer researching options, <strong>The</strong> <strong>Gougeon</strong> <strong>Brothers</strong> on Boat Construction provides a solid understanding of available choices and their nuances. Changes to the 5th Edition To make <strong>The</strong> <strong>Gougeon</strong> <strong>Brothers</strong> on Boat Construction a richer resource for the 21st century reader, we have chosen to revise, reorganize, and update the book, but not to rewrite it. To edit out less popular construction methods like stressed skin or stringer-frame construction or replace fundamental building disciplines such as lofting with modern counterparts like computer-assisted design (CAD) would rob the reader of choices. While, after 25 years, the book includes some things that we would no longer do, this information provides a historical perspective on how “modern” wood/epoxy construction evolved and potential techniques that could still be of interest to current builders. For clarity, we have reorganized the 5th edition into six sections: • Fundamentals of Wood/Epoxy Composite Construction • Getting Started • Core Boatbuilding Techniques • First Production Steps • Hull Construction Methods • Later Production Steps
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Selected Bibliography While the fol
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