The Gougeon Brothers on Boat Construction - WEST SYSTEM Epoxy

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344 Later Production Steps Figure 27-14 Golden Dazy’s cockpit, viewed from the bow. We always begin cockpit construction by building the cockpit floor. <strong>The</strong> cockpit floor, like the floor of a house, serves as a foundation on which to erect the walls. We favor sandwich construction with a honeycomb core for cockpit floors, but a standard framework-supported floor similar to that used on the deck also works well. After we have constructed the Deck Beam Epoxy/Filler Cleat Figure 27-16 Cockpit construction details. Sides attached with sole dropped down onto cleats for bonding. Fillet Molding/cap Plywood cockpit sides Honeycomb core Optional fillet permits easy cleaning (sole can be painted) Cockpit sides with cleat attached to support cockpit sole Honeycomb core Built-up coaming with teak cap Deck beam Carling Cockpit sides Plywood lip Limber hole Hinged-top wet locker Beam Figure 27-15 A typical cockpit seat section detail. Sole floor, we saw cockpit sidewalls of appropriate plywood thickness and bond them to the completed floor to form a ready-to-install cockpit, as shown in Figure 27-12. Cockpit sole and sides preassembled then fastened to longitudinal stringer. Sole Beam Stringer Frame built into panel/core cockpit sole is relieved slightly. This allows the builder to visually inspect the joint as thickened epoxy is forced into the void. Plywood Deck Deckbeam Plywood sides Shelf or cleat carrying cockpit sole beams
Chapter 27 – Deck Construction 345 <strong>The</strong> cockpit may be much more elaborate than this, with seats and lockers underneath. You can also add these before you install the whole unit in the hull. Positioning the cockpit in the hull is not difficult. It must be centered and set at the right height in relation to the sheer dimension or possibly to a waterline. Usually, there is at least one bulkhead in the vicinity of the cockpit, and you can cut this out to the exact dimension of the cockpit shape and use it as a positioning point for placement of the cockpit. With this initial support, you can true up the cockpit to the final dimension required. You may need temporary support to hold the cockpit in proper position until you can install enough deck framework to hold the cockpit installation rigidly in place. Decking Over To final fair the deck framework, use essentially the same methods that are used to fair up a hull. Because the deck surface is almost flat in comparison to the curves on a hull, it is easy to see and correct imperfections, so fairing the deck framework is much less difficult than fairing a hull. Long-bed hand planes are ideal for fairing up this large, flat surface area. A large plywood batten measuring about 1' wide � 8' long (300mm � 2.4m) also helps indicate how the plywood will lie on the various frame members. After the deck framework is faired, it is ready for the plywood decking. Decking thickness depends upon a number of factors, such as boat size and type, amount and spacing of supportive deck framework, and the Figure 27-17 <strong>The</strong> foredeck and beam fairings on Rogue Wave are plywood over stringers. <strong>The</strong> cabin areas are sandwich construction using resin-coated paper honeycomb core. type of service that the boat is likely to see. Generally, decks don’t have to be as thick as hulls. A hull must be thick enough to withstand impact loads of hitting floating debris and the constant hydrodynamic loads of waves. <strong>The</strong> heaviest potential load on a deck is from a large boarding sea, and this enormous load, while awesome, is not particularly high on a pounds-persquare-foot basis when compared with the loads that a hull must withstand. For most decks, the human body presents the greatest concentrated load the deck will ever have to withstand. Thus, our minimum criterion for a successful deck is that it be strong and stiff enough to prevent any substantial deflection when it is walked upon. A continually deflecting deck is likely to have a short life span, failing through fatigue at an inopportune moment. In the end, there are no firm guidelines for deck thickness. If you use thin plywood, you will need more frames; if you use thick plywood, you will need fewer frames. A thin skin with a number of lightweight frames is lighter than a thicker plywood deck, but it also takes more time to build. We covered the deck framework for the 42' (12.8m) Golden Dazy, shown in Figure 27-5, with two layers of 1 ⁄4" (6mm) plywood and laid 1 ⁄8" (3mm) teak laminate over the ply. <strong>The</strong> resulting 5 ⁄8" (9mm) deck was considerably thinner than Dazy’s 11 ⁄8" (28.5mm) thick hull. <strong>The</strong> frame-supported deck on Rogue Wave, a 60' (18.2m) trimaran, on the other hand, was only 3 ⁄8" (9mm) thick. Many small day racers have well-supported 1 3 1 ⁄8" to ⁄16" plywood decking. Ollie’s deck is 5-ply ⁄4" plywood over light deck beams at 7" (175mm) spacings. Apply plywood decking in the same manner that you apply plywood panels to the hull framework in standard hard chine construction. (See Chapter 24.) As is the problem with hulls, decks normally present too large an area to cover easily with one prescarfed panel. <strong>The</strong>refore, we apply the largest-sized panels that we can cut out of a 4' � 8' (1200mm � 2400mm) sheet of plywood and join them in place on the deck, using a deck beam or stringer as the point at which to make a scarf joint. Planning the scarf positioning may be a little bit more difficult on a deck than on a hull because of potential obstructions that must be fitted to, such as the cabin walls, hatches, and cockpit. Because the underside of the deck will be seen by all, try to do the best
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The Gougeo
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Gougeon Br
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iv Table of Content Getting Started
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vi Table of Content Chapter 17 Mold
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viii Table of Content Later Product
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x Preface The brie
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xii Table of Content
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2 Introduction With the help of fri
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4 Introduction
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Modern Wood/Epoxy Composite Boatbui
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Chapter 2 - Modern Wood/Epoxy Compo
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Wood as a Structural Material CHAPT
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Chapter 3 - Wood as a Structural Ma
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WEST SYSTEM ® Products This chapte
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Chapter 4 - WEST SYSTEM ® Products
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Hull Construction Techniques— An
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Chapter 5 - Hull Construction Techn
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Getting Started Chapter 6 Before Yo
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46 Getting Started Finally, should
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48 Getting Started Designers’ fee
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50 Getting Started
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52 Getting Started Material Price/b
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54 Getting Started between layers o
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56 Getting Started mast; sails and
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58 Getting Started
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60 Getting Started and it is import
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62 Getting Started necessity. We al
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64 Getting Started Grit refers to t
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66 Getting Started An efficient flo
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68 Getting Started Ridge Pole Frame
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70 Getting Started
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72 Getting Started unimproved lumbe
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74 Getting Started If it is not yet
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76 Getting Started chapters, we adv
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78 Getting Started
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80 Getting Started The</str
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82 Getting Started cures quickly to
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84 Getting Started Evap. Rate LEL2
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86 Getting Started 4. Use wet, rath
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88 Getting Started
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Laminating and Bonding Techniques <
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Chapter 11 - Laminating and Bonding
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Scarfing Scarfing remains an essent
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Chapter 12 - Scarfing 109 and used
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Chapter 12 - Scarfing 111 Productio
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Chapter 12 - Scarfing 113 Figure 12
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Chapter 12 - Scarfing 115 Figure 12
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Chapter 12 - Scarfing 117 bevels on
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Synthetic Fibers and WEST SYSTEM ®
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Chapter 13 - Synthetic Fibers and W
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Hardware Bonding As stated earlier
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Chapter 14 - Hardware Bonding 131 s
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Chapter 14 - Hardware Bonding 133 t
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Chapter 14 - Hardware Bonding 135 A
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Chapter 14 - Hardware Bonding 137 F
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Chapter 14 - Hardware Bonding 139 e
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Chapter 14 - Hardware Bonding 141 F
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Chapter 14 - Hardware Bonding 143 W
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Chapter 14 - Hardware Bonding 149 K
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Coating and Finishing Broadly, the
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Chapter 15 - Coating and Finishing
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First Production Steps Chapter 16 L
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166 First Production Steps Hull Lin
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168 First Production Steps Figure 1
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170 First Production Steps 1" X 4"
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172 First Production Steps After ch
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174 First Production Steps did the
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176 First Production Steps stem or
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180 First Production Steps case you
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182 First Production Steps curve th
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184 First Production Steps Mark the
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186 First Production Steps
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188 First Production Steps will be
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190 First Production Steps Notches
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192 First Production Steps image an
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194 First Production Steps probably
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202 First Production Steps Setting
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204 First Production Steps To detec
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206 First Production Steps Beveling
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208 First Production Steps Section
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210 First Production Steps Stem lam
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216 First Production Steps Keel Fai
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Building a Mold or Plug A mold is a
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Chapter 20 - Building a Mold or Plu
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Laminating Veneer Over a Mold or Pl
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Chapter 21 - Laminating Veneer Over
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Stringer-Frame Construction While s
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Chapter 22 - Stringer-Frame Constru
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Strip Plank Laminated Veneer and St
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Chapter 23 - Strip Plank Laminated
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Hard Chine Plywood Construction A s
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Chapter 24 - Hard Chine Plywood Con
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Page 307 and 308: Compounded Plywood Construction Mos
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The Gougeo
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Selected Bibliography While the fol
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The Gougeon Brothers on Boat Construction - WEST SYSTEM Epoxy

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