I post these rather lengthy notes for a likely “I was there many moons ago” snicker from the wise long time builders and maybe an encouragement for those embarking on the voyage for the first time:
Timing saves time. A ton of it. Epoxy is all about timing. Example: shaping a fillet too early lets it sag, too late is a disaster that leads to prolific swearing. Think taffy you forgot in your back pocket on a hot day…
Know when to say when. Perfect truly is the evil of great in this process, and that isn’t to say you shouldn’t strive for beauty and function. Example: oversanding to get the perfect finish, only to take that first swipe with denatured alcohol to recognize bare wood again.
In fact, embrace the imperfections - they’re part of the story like any beautiful boat. One of my most memorable build stories was when I glassed the hull. The manual said to reserve several hours of undistracted time and be ready to work quickly. The epoxy over the bottom went great, and as I poured a 12 oz cup to drizzle over the sides the tornado sirens went off. And my wife said it was directly over our town. I rushed to scoop the epoxy up as fast as possible and ran for the basement. All turned out fine, no damage or injuries anywhere, but there was a small spot that came out fine but not perfect. I decided to embrace it and not fix it - it’s part of the journey.
Pick your battles. I spent far too much time (and epoxy) trying to get the inside bow fillets just right and shapely, and then realized they would be buried in a compartment only visible after the boat would be split in half…. Similarly, I stopped sanding the snot out of the skiff bottom when I realized that if we see the bottom again while in the water, we probably have bigger problems than paint sheen…
Don’t forget this is for fun, and when it isn’t take a break. Rushed or frustrated work is almost always subpar and feeds more work. I’ve learned that in my furniture building and tried to apply it to boatbuilding, but warmer days and thoughts of being on the water were hard to fight.
Practice on a piece of scrap wood first. I stitched together some scrap plywood and practiced fiberglass taping, fillets and sanding. It’s a lot easier to learn how to make a good fillet than to sand a bad one…
Fiberglass tape was invented by the devil. Still learning how to bed it without making waves or a hairball on the ends that will outlive the earth, and I’m pretty sure the thicker edge along one side was the idea of a sandpaper company.
I think I now own the majority of the spring clamps in my county. I bought so many spring clamps that I get a holiday card from the manufacturer. And I think I could use a few more.
Marine paint is a humbling substance. The first swipe of the brush starts with “I bet Mystic Seaport is going to want to display this fine work” and ends with “at least it floats… hopefully”. The slightest of blemishes show, but I’ve learned that they are each part of a story that’s far more valuable to me than perfection. And they’ll all become invisible in the joy of being on the water.
The manuals are fantastic - the best I’ve seen for such a process. But like my father says about recipes, they’re a diving board from which you explore. He also says there’s more than one way to skin a cat. As I progressed through the build I became courageous enough to do some things differently, and I think found a way to make things more efficient for me with the tools in hand. And, it all worked out well. Take the dive - it’s been a great swim!
Already thinking of my next build…