Phase 2

This page and all links within will be dedicated to the building of the hull. That includes everything up to rolling the hull.

Phase 2 Checklist

1. Building form set up
2. Build frames
3. Attach to building form
4. Build and attach 
   1. stem
   2. chines
   3. longitudinals
5. Fair hull
6. attach bottom planking
7. attach side planking
8. Fair hull
9. encapsulate/glass hull
10. attach spray rail and skeg
11. drill all thru holes and encapsulate
12. paint hull
13. Build roll frame/support
14. roll frame

Phase 2 Materials list(doesn't include stretch yet)

• Plywood (9mm - 3/8": 6mm - 1/4": 12mm - 1/2": 18mm - 3/4")
  • okume 1088 - $1,747.60
    • 1/4 - $291.20
    • 3/8 - $519.60
    • 1/2 - $337.80
    • 3/4 - $599.00
  • meranti 1088 - $1,421.40
    • 1/4 - $216.40
    • 3/8 - $429.00
    • 1/2 - $297.60
    • 3/4 - $478.40
  • Marine DF AB - $1,178.30
    • 1/4 - $267.60
    • 1/2 - $575.10
    • 3/4 - $335.60
      • Transom, stem, breasthook, floor timbers - 4 - 3/4" 4'x8'
        • okume 1088 - $149.75/bd - $599
        • meranti 1088 - $119.60/bd - $478.40
        • marine DF ab - $83.90/bd - $335.60
      • Gussets, floor timbers - 3 - 1/2" 4'x8'
        • okume 1088 - $112.60/bd - $337.80
        • meranti 1088 - $99.20/bd - $297.60
        • marine DF ab- $63.90/bd - $191.70
      • Bottom Planking - 4 - 1/4" 4'x24'
        • okume 1088 - $72.80bd - $291.20
        • meranti 1088 - $54.10bd - $216.40
        • marine DF ab - $41.90/bd - $267.60
      • Side Planking - 2 - 3/8" 4'x27'
        • okume1088 - $86.60/bd - $173.20
        • meranti 1088 - $71.50/bd -$143.00
        • Marine DF AB -  $63.90/bd - $127.80
          • have to use 1/2"
      • Decking - 4 - 3/8" 4'x8'
        • okume1088 - $86.60/bd - $346.40
        • meranti 1088 -$71.50/bd - $286.00
        • Marine DF AB - $63.90/bd -$255.60
          • have to use 1/2"
• Lumber
  • Building Forms
  • Framing  - $1,232.6 + 50%extra $600
    • Frames - ~$575
      • 1-1/4" x 10"  - 20'(20.83bf=$124.98)
      • 1-1/4" x 6"  - 50'(31.25bf=$187.50)
      • 1-1/4" x 5"  - 80'(41.66bf=$249.96)
    • Keel -  $24
      • 1" x 6"  - 38'(4bf=$24)
    • Bottom battens - $243.90
      • 1-1/4" x 3" - 130'(40.65bf=$243.90)
    • Side battens  - $54
      • 1" x 2"  - 54'(9bf=$54)
    • Chine logs  - $78.12
      • 1" net x 2-1/2"  - 50'(13.02bf=$78.12)
    • Raised Sheer Clamps  - $60.90
      • 5/8" net x 1-1/4"  - 130'(10.5bf=$60.90)
    • Sheer Clamps  - $154.68
      • 1/2" net x 1-1/4"  - 330'(25.78bf=$154.68)
    • Carlings  - $42
      • 1" x 2"  - 42'(7bf=$42)
• Epoxy $1,808.40
  • Poxy-Shield - 1.2gal kit $124.75 - 6 gal kit $578.90
    • estimate need about 16 gal, get 3- 6gal kits $1,736.70
  • #1 Silica filler - $15.30/lb or $312/22lb
    • estimate need 4lb $61.20
  • MicroSpheres - $5.25/lb or $86.63/30lb
    • estimate need 2lb $10.50
  • Encapsulating
    • PoxyShield 
      • estimate need about 4.5gal
    • Fiberglassing
      • PoxyShield
        • estimate need about 7 gal
    • Adhesive
      • PoxyShield
        • estimate 3 gal
      • #1 Silica Filler
        • estimate need 3 lb
    • Fairing
      • PoxyShield
        • estimate need 2gal
      • #1 Silica Filler
        • 1lb
      • MicroSpheres
        • 2lb
• Fiberglass - $573.40
  • Estimate needed exterior hull
    • 500sq ft = ~ 55.6sq yd of 50"cloth
      • buy 1 roll for extra $487.50
    • 189ft = ~63yd of 8" tape
      • buy 2 rolls - $85.90
  • 7.5oz E glass cloth
    • 50"wide
      • $487.50/125yd roll
    • 8" Tape - 8.7oz cloth
      • $42.95/50yd roll
• Fasteners
  • Screws - $1,073.40
    • #8- 1" - 1200 @ 20.85/100($250.20)
    • #8- 1-1/4" - 2000 @ $24.25/100($490)
    • #8- 1-1/2" - 200 @ $30.50/100($61)
    • #10- 2" - 200 @$59.40/100($119.20)
    • #14- 3" - 20 @$153/100($153)
  • Nails - $87.50
    • #12- 1" - 4lbs @$17.50/lb($70)
    • #12- 1-1/4" - 1lbs @$17.50/lb($17.50)
  • Carriage Bolts
    • 3/8"
      • size from work
      • need at minimum 3

Extension Additional Materials

Plywood:

• Each planking and deck layer will be increased by 2 feet
  • Okume 1088 - $246
    • 1/4 - $$72.80
    • 3/8 - $173.20
  • Meranti1088 - $197.1
    • 1/4 - $54.10
    • 3/8 - $143.00
  • Marine DF AB - $169.70
    • 1/4 - $41.90
    • 1/2 - $127.80
      • Side planking 3/8"
        • 2 layers
          • 4ft
          • 1- 4'x8' will suffice 
            • okume1088 - $86.60/bd - $86.60
            • meranti 1088 - $71.50/bd -$71.50
            • Marine DF AB -  $63.90/bd - $63.90
              • have to use 1/2"
        • Bottom planking 1/4"
          • 4 layers
            • 8ft
            • 1 - 4'x8' will suffice
              • okume 1088 - $72.80bd - $72.80
              • meranti 1088 - $54.10bd - $54.10
              • marine DF ab - $41.90/bd - $41.90
        • Decking 3/8"
          • 1- 4'x8' will suffice
            • okume1088 - $86.60/bd - $86.60
            • meranti 1088 - $71.50/bd -$71.50
            • Marine DF AB -  $63.90/bd - $63.90
              • have to use 1/2"
        • Gussets and floor timbers are the same
        • Transom is the same
        • Stem and Breasthooks are the same

Lumber: 

• Each Batten between frames is a few inches longer
• each chine, sheer, keel, etc is 2 ft longer
  
  • 49.625bdft x $6/bdft = $297.75
    
    • 2 chines - 8 ft(4 -2ft layers) -1"x2.5" = 20bdft
    • 2 sheers - 4 ft - 1/2"x1.25" = 2.5bdft
    • 2 raised sheers - 4 ft - 5/8"x 1.25" = 3.125bdft
    • 1 keel -4ft(2 - 2ft layers) - 1"x6" =  24bdft
• Frames are the same size
  • Frames 1-6 are spaced 4" wider than non stretched boat.
  • Stem, frame 7, and breasthooks are same as non stretched boat.

Fasteners:

• ​Screws -$45.10
  • #8- 1" - 20.85/100
    • Sheer clamp second and third layers
      • ~32
    • Side planking sheers and chines
      • ~24
    • Side planking side battens
      • ~16
    • 1 box should suffice - $20.85
  • #8- 1-1/4" - $24.25/100
    • keel lam
      • ~8
    • Raised sheer clamp second layer
      • ~16
    • Bottom decking @ chine and keel
      • ~24
    • Bottom decking @ battens
      • ~18-24
    • 1 box should suffice - $24.25
• Nails  - $17.50
  • #12- 1" -$17.50/lb(about 305 nails)
    • bottom planking first layer
      • ~32-40
      • 1lb will more than suffice

Fiberglass:

• 7.5oz cloth
  • 50" wide
  • 8" wide tape

Epoxy:

• Encapsulating
• Gluing

Frames

Building Forms

Standard 2x6
set into concrete footings

Fairing Hull

Fiberglass/epoxy bottom

• Fiberglass
  • at least 7.5oz cloth

Skeg and Spray rails

Install skeg and spray rails

Painting bottom

At very least need to paint the bottom up to the waterline. - $1,069.86

• primer
  • interlux primekote - $205.98
    • $102.99/gal
      • need 2 gal
        • thinner needed 2333n
          • 25-30%
  • 450sqft/gallon
  • min, 2 coats
• paint
  • Interlux VC Performance Epoxy
    • bottom paint, non ablative
    • 220sqft/gal
    • White
      • $60.99/qt kit 
      • $194.99/gal kit
    • Needs solvent wash before application 
      • Interlux 202 Fiberglass solvent wash
        • $18.99/qt
        • $52.01/gal
    • Needs thinner
      • Interlux 2316N Spray reducer
  • Interlux Perfection - $863.88
    • topside paint, good enough for short time underwater
    • Royal Blue
      • 71.99/qt
        • 4qt=1gal
        • need 3 gal
      • 475sqft/gallon
        • thinner needed 2333n
          • 5-10%
      • 3-4 coats
  • Blue Water Marine Paint System
    • Wash
      • 973 Dewaxer - $24.45/gal
    • Primer
      • Bottom Protect Primer 8000A - $68.45/gal
        • ~400sqft/gal
        • 3-5 coats
    • Paint
      • Revolution - $157.04/gal
        • topside paint good for up to 7 days in the water
        • ~400sqft/gal
        • lots of color choices
        • 2-4 coats
      • thinner needed
        • ​​​974 thinner - $24.45/gal

Fair and drill for running gear

Drill holes

• rudder
• prop shaft

Building flipping/rolling frame

Roll frame doubles as Hull support until it is put onto trailer.
basic 2x6 lumber with plywood gussets for frame at minimum frames 1-4-7
basic 2x6 lumber with 2x6 braces for longitudinals

• longitudinals can be used as a pattern for the trailer bunks.

Flipping Party

Throw a party for all who come to help flip the boat.

• Remove from building form
• Roll hull
• Remove building form
• Move hull
• Level and secure frame.

​Party time!

Phase 1 - Planning

Phase 3 - GUTS