The Gougeon Brothers on Boat Construction - WEST SYSTEM Epoxy

Laminating Veneer Over a Mold or Plug
This chapter describes in detail the process of laminating layers of thin wood veneer over a mold or plug
such as those described in the previous chapter. <strong>The</strong> process of laminating veneers is more commonly
known as cold molding, and what follows is one of the best available descriptions of the process. While
popular in the early years of wood/epoxy construction, the cost of building a throw-away mold, the inability
to include interior structure in the set-up, and labor required make cold molding less attractive than other
methods of boat construction. Cold molding is still utilized in conjunction with strip plank construction on
larger boats.
When the mold is faired, it’s time to begin planking.
Your plans will specify the number of layers of veneer
or plywood the hull requires. Although this count may
vary from project to project, laminating techniques do
not. A hull may be made of sliced veneer, plywood, or
stock which you have sawn yourself. In this chapter, for
simplicity, we use the term veneer to refer to all of
these materials.
<strong>The</strong> general procedure for laminating hulls over a mold
is not complicated. If your wood doesn’t have a single
straight edge, you will have to cut one. <strong>The</strong>n spile each
piece, trimming it so that it lies true against its neighbor
at a desired angle, apply thickened epoxy, and staple it
to hold it in place until the epoxy has cured.
<strong>The</strong> first layer of a laminated hull is the most fragile.
Edge glue its pieces and staple them directly to the
mold. Carefully remove excess adhesive and staples.
Sawn edge
Clamp
Circular saw
Veneer 2" X 12" Base
Figure 21-1 A method for cutting a straight edge on veneers.
CHAPTER
21
Use thickened WEST SYSTEM ® epoxy to laminate a
second layer of wood at an angle to the first and staple
through the first layer to the mold. Continue laminating
in this way, stapling subsequent layers to each other but
not to the mold until the hull is as thick as you want it.
Fair it, finish it, and remove it from the mold.
Preparing the Stock
You can use any of several different types of wood to
laminate your hull. In most cases, boatbuilders use 1 ⁄8"
(3mm) commercially sliced veneer, but you may choose
plywood or saw the lumber yourself. <strong>The</strong> first step is
to make sure that every piece has one straight and true
edge. Later in this chapter, when we discuss spiling,
the reasons for this will be apparent.
Plywood has a manufactured straight edge accurate
enough to require no further trimming. Veneer,
1" X 8" Straightedge
Veneer
Rough edge