Day 25

Decided to fiberglass the floor today before the flip. I also did a mild amount of sanding on the tape ends that were cured.

Cleaned the shop- my least favorite part.

Trying to figure out the best way to lay out the fiberglass on the bottom. I don't want to waste material because it will be close with the amount I purchased. A lot of angles to deal with.

Day 24

Thought I had finished all the taping- but... part of the tape didn't adhere well to the rim so I cut it off/added filler and am waiting for it to dry. Tomorrow I will sand it down and retape the area. I also will start the sanding process of the tape ends. I want to get this done and over with before I flip it. Then after the bottom is finished I will flip it back and add the last of the fiberglass cloth and epoxy to the top and inside, then paint.

I also laid out cup and shell holders for the back seat and the front bench. I could probably have bought them but since I'm all wood I need to stay that way.

Been thinking about a door for the front storage. I made the hole to big and would like to keep things from falling out. However, the extra room for foot space for the front passenger is nice... who knows?

Day 23

It ia snowing like the North Pole today so I am stuck at home. Spent the morning filleting and fiberglass taping the inside and top of the boat. Trying to get the corners to stick is a bear. Hard radius' and fiberglass tape do not mix. However, I think it ended up pretty good. My guess on weight is going to be 180-190 lbs. Right now I am at 152 lbs.

The inside is completely fiberglassed, fillet, and has one coat of epoxy on the bare wood. The pontoons are just about finished at the top portion. I am waiting for the 1st set to dry so I can cut it and apply the rest.

As you can see my shop is small, but there is enough room to move around. I still need to sand the tape ends after it dries and apply another coat of epoxy.   The picture is of the back of the boat.

Front inside of boat. The hole in the seat is for the switch panel.

My new to me, but used Evinrude 8 hp 2-stroke tiller motor. The powerpack is new, lower unit is in great condition, carb cleaned, new paint (doesn't matter though because it is going to be OD Green eventually). Got it for a steal.

Day 22

I finally cut and glued the top of the boat today. It is in clamp and dry. I also did some misc. taping inside the cockpit. I think I am over fiberglassing; but I don't want the boat to come apart later down the road. Kind of excited- the boat is beginning to look like a boat.

Day 20

Decided on the middle storage/seat and finished it. I also cut and glued the motor well/rear storage area today.

In the picture you can see on the bottom of the seat where I inserted 2 drains running from the front to the back. They are cut in half PVC pipe and fillet in. The seat/hatch is 24" wide and all the top is routered with a 1/2 round.

The motor well/rear storage is 14" deep. The openings underneath are different sizes to fit a trolling motor battery, gas tank, and other items. The motor well is 6" deep and I will add scuppers to the transom at the end. The well doesn't extend to the outermost part of the transom cut but that's OK. Gas tank storage was more important (I hope).

Tomorrow I plan on starting the top piece to the pontoons and front. From there I will tape it all and flip it. Once flipped I will finish the bottom completely with fiberglass cloth, epoxy, Kevlar, and paint.

I have decided to add rubber rub rails around the outside instead of wood. So the list grows of things I still need to purchase- rub rails, paint, scuppers, thru scussions for the gas lines, motor, and trailer.

Day 19

Today I set the front storage hatch front, cut and glued the middle storage/seat sides and fillet and fiberglassed taped all of it. I also put a coat of epoxy on the entire inside. Debating on setting the top and rear splash well/storage before turning it over and completing the bottom. I don't want it to get to heavy before I flip it. See where I stand tomorrow and how I feel. I have a lot of sanding to do.

The middle seat/storage is 12 1/2" tall from the inside and 11 1/2" wide from inside. I did this to accomodate a battery and it's box. I haven't built the seat yet because I don't know exactly how I want the seat and hatches to work. I only know it will be 3/4" plywood.

I have been adding up the weight and right now I am at 145 lbs with all plywood and all fiberglass/epoxy.

Going to look at a motor tomorrow as well- 9.9 hp Mercury 2-stroke.

Day 18

I went hunting for a few days and am back. Today I sanded the pontoons, glued the floor in, cut an glued the transom, cut and glued the bow, and cut the front storage hatch.

The picture is of the bow. I still need to fillet and fiberglass tape all of it.
You can see the transom in the back. It is a total of 19" tall for the splash rails. The angles are 45 degree and it is 18" wide at the bottom and 15" from floor for a short shaft motor.

Picture is of the bow storage hatch opening. The rails are 4" from the sides and 2" from the top and bottom. It has been routered with a 1/2" round over bit. The front piece of the bow is 4" tall. I also spent some time refilling the areas of the pontoons and the connections between the transom/floor and the bow/floor pieces with an epoxy/sawdust mixture.

Day 14

Spent the weekend hunting (or part of it- thanks to DH it was only Saturday). My plungers haven't come in yet but I did cut the inside pieces of the pontoon. They are now sitting clamped and drying.

If I had more room and tools I am sure the boat would be further along. Most of the time is spent waiting on adhesives to dry and things to arrive in the mail.

Next step is too rasp down the high spots on the foam and cut/apply the bottom, front, and back pieces. These I will adhesive and nail to speed the process along so I can epoxy the corners.

From there it is floor, front, and transom time.

Went and looked at a trailer yesterday and some fool thought his rusted-out trailer was worth a fortune. Turned him down.

Day 12

The epoxy came in but the pumps didn't. Therefore, I jimmied a pump and scarfed the plywood last night. Today I cut the two outside pieces for the pontoons and laminated them to the foam with adhesive to hold them in place until filleting. I have a few areas needing sanding on the edges because I'm 1/16- 1/8th off; but I am very pleased so far (using a skill saw has its dissadvantages).

I clamped, taped, and weighed down the pieces until dry. I used everything I could to add weight (probably need more clamps but I'm cheap on buying tools).



The two pieces cut for each side were the upper outside piece- 4 1/8" x 11' 2 3/4" and the lower outside piece- 13 7/8" x 11' 2 3/4" with the front and rear angle. Total of 4 pieces cut and glued.


Tomorrow after duck hunting I plan on cutting the inside pieces that wrap around the floor and setting them. Then add the floor, transom, and front. Then onto the inside of the cockpit above the floor. From there I will add the top and bottom of the pontoons, fillet and sand all corners.

Day 10

No epoxy so I went and picked up wire and a few odds and ends for the boat. Epoxy should be here tomorrow.

Day 8 & 9

No epoxy. I should have ordered it earlier but there is no deadline. It is supposed to arrive on the 14th (2 more days) so I have been redesigning the interior layout. I really do not like the bench seat idea in the middle because it limits floor space so I have been debating on a battery box with a seat on it. The only problem is hiding the wire in the floor. Also looking at the rear seating and storage/motor well. I think I have it figured out. I will sketch it or post a pic eventually for clarity.

Found a trailer for little too nothing and am going to look at it this week. It's galvanized and that's a plus.

Decided on a 9.9 hp motor. Maybe a little big, but it needs to push through ice sometimes.

Day 7

Still waiting on the epoxy and couldn't take the idea of the plywood being upside down on one end of the scarf. So, I turned 2 pieces over and around and re-scarfed them. Now the plywood faces will match.

Decided on the steps to attach all the skins and epoxy application. It is as follows:

1. Glue scarfs
2. Cut and apply the outside
3. Cut and apply the inside
4. Cut and apply the bottom
5. Cut and lay floor, transon, and front
6. Cut and lay the inside wall of the pontoon above the floor
7. Fillet the inside and outside
8. Cut top and front storage bulkhead, middle bench sides and fillet
9. Fiberglass bottom and sides
10. Epoxy inside (I haven't decided if I am going to fiberglass the inside yet)
11. Cut and set transom and splash guards (researching glues/etc to make them removable if damaged)
12. Paint
13. Electrical
14. Set in all hardware

I am probably missing a step, but it can be added as I go- or fixed.

Day 6

Picked up the 1/8" plywood and scarfed it today. Truely a pain in the butt trying to scarf plywood with a belt sander and block plane. But, it was a successful mission and I am pleased with the results. I did make one mistake and not turn 2 pieces over out of the 4 so the same wood grain would show after gluing, but after the paint no one will notice but me.

Picture is of plywood after scarfing. The plywood ratio turned out to be a 2 1/4" bevel for each piece.





Ordered the epoxy, fiberglass tape, mixing cups,woodflour, and pumps today. I chose West Systems 207 I believe. It's amazing about who thinks theirs is the best; but after researching forums I found West 207 came up more being used. Raka was also mentioned without problems but was more expensive.

Name

Since the plywood hasn't come in I have spent my time towards the boat thinking about a name. I have come up with a few, but "EDITH" seems to sound right. I like that name- it was my grandmothers and she was a vibrant, strong woman with a large dose of class. She also was an avid hunter when she was young and fished until her death. The name fits.

Day 5

Added the inside foam pieces to the pontoons. Adding the 2" will increase bouyancy, support the floor/front/transom, and make the pontoons "beefy" because it will need to crush ice during duck season. The ice issue bothers me with the fiberglass bottom. Researching other alternatives to prevent damage. It wasn't really a concern because usually the ice doesn't get to thick. However, yesterday we broke 1-1.5" ice going into the blind and it got me to thinking. Also brought up the concerns of punctures with rocks on a lake I fish. Maybe a kevlar bottom?

Finished rasping everything square, checked measurements, and waiting for adhesive to cure completely. My shop is a little cold so I want it good and dry. Also its duck season so my thoughts and motions have been hunting for ducks.

Picture is of the pontoons  upside down and taped together. The crossed out lines are from adjusting my angles to suit my personal ideas.

(Next step is to clean up the shop. The foam sticks to everything).





Ordered the plywood and waiting for it to arrive.

Researching motor size and getting prices (also looking for a good used). I think it needs a 9.9 hp, but would like to go 15 hp if possible.

Researching motor wells as an addition to prevent some water intake.

Looking for a good used trailer.

Day 4

Last night I couldn't sleep so I filled the front, rear, and middle of the pontoons with expandable foam. Woke this morning and the foam was dry. So-

Today I took the pontoons out of the jigs and rasped them to equal lengths and squared them up. I still have a little more work to do on them in the rasping regards; but I need to install the inside pieces for the front and rear part of the pontoons. Right now they are 6" wide at the top and 4" at the bottom. On the front and rear, outside of the cockpit, I am adding another 2" foam piece for buoyancy. After I cut, glue, and rasp them I will start on the cockpit floor and transom.

I haven't decided on whether to use 1/2" or 3/8" for the floor. I'm going to the building supply store and jumping up and down on both types and decide then. I think 3/8" will do since I am fiberglassing the bottom, but not sure.

Day 3

Finished gluing up the pontoons today and cut the front and rear slope. Waiting for it to dry.

Front view before filling with foam.

Pontoons in dry. The paint cans, duct tape, and jig help hold it all in place.











Also went to BPS and bought electical  supplies to template skins.

Design Change

During day 2 I made a change in the cockpit and decided on bench seating for more storage and structural integrity. Also I moved the switches and a 12V to the middle seat.

Day 2

Today I glued up more of the pontoons and ran the conduit for the electrical. I also went to the local building supply mega-store and picked up some stainless steel screws, adhesive, conduit, and 1 piece of 2" foam.

Laying out the pontoon for another round of adhesive.

Conduit for electrical and pontoon glued in place. I still need to glue the outside piece, square it up, and cut the front and back pontoon angles. The pontoons lay in 3 jigs I made and are taped until the glue dries.