Build
your own boat - Over
the years the New Zealand boatbuilding scene has changed
from the traditional bunch of guys getting together to build
their own boat.
It was often that a good session in the pub or club would
end with the resolution of a few mates to build their own
boat. Normally a pooling of resources such a s a boatbuilder,
sailmaker and maybe a sailmaker and a couple of hangers
on being a good combination.
With modern materials and building techniques developed
by our designer it is easier than ever to build your own
boat.
Steve Thompson attempts to explain why in these pages.
Modern
Materials - The
advent of the new resin systems with various resin curing
times and uses as glue or fillers developed by the Gougeon
Brothers has made building your own boat achievable by the
amateur boatbuilder.
The latest fiberglass cloth developments have also made
life easy for the builder. The use of high end cloths like
carbon fiber makes a boat stronger and easier to build because
of their easier handling characteristics.
While it is not possible to get the absolute best results
without superior knowledge and equipment the strength of
the newer materials means that even if an amateur builder
achieves 90% of the strength achieved by the professional
builder he is well ahead of building boats by more traditional
methods.
Links to material information
Epoxy
Usage
Fiberglass
construction
Latest
Design Techniques - The
latest computer aided draughting, CAD, techniques had made
a great change in the boatbuilding process. Nowadays the
designer completes a lot of the work the builder has traditionally
done.
For instance a designer nor fully fairs a boat on a computer
to a very high accuracy alleviating the need to loft the
boat on the floor. We can therefore create full size patterns
that are very accurate for the entire boat. Also the designer
can transfer data direct to computer driven cutting machines,
CNC Machines, to allow full size components to be directly
cut.
The web has also simplified the transfer of data and drawings
to the extent that drawings are now fully drawn on computers
and delivered via email for the builder to print.
Study
Pack - To
help the prospective builder assess the cost and building
requirements for a boat we offer a set of study drawings
and building information.
This may include:
- Rig and sail plan
- Construction material list
- Hardware list
- Manufactured parts
- Build methodology
- Photos
- Performance data
The study packs are offered for a fee together with our
confidentiality agreement. The fee for the study pack is
deducted from the cost of drawings when purchased.
(www.tboat.com/payment.html)
Custom
Construction Methodology - There
are three different methods we recommend for building custom
boats. The method used depends mainly on the number of boats
to be produces by the builder.
Production boats are generally built using full female moulding.
One
off Amateur construction
Hull
and deck built over female battened moulds without vacum. The
foils are shaped from full size patterns supplied.
2-3 boats
Hull
is built over a female mould with partial vacum
The Deck is built over a female MDF mould with vacum.
Internals are partially built from MDF female moulds.
The foils are built from CNC cut MDF moulds with the bulb
cast in lead and attached after the keel is built.
More
than 3 boats
Hull
is built over a male mould with vacum
The Deck is built over a female MDF mould with vacum.
Internals are built from fiberglass female moulds.
The foils, including bulb are built from female fiberglass
moulds with the bulb integral with the keel.
One
off Amateur construction – Description
- The hull frames are cut out using the full size templates
or cut using a CNC machine.
- The deck frames are made and fastened to the hull frames
- The frames are setup on the floor or building frame ready
to plank.
- Stringer up the deck mould using flat panels on the horizontal
surfaces.
- Fit the foam to the deck and surface with the interior
laminate.
- Paint the inside surface where required and cut into 4
pieces along the rebates allowed before removing from the
mould.
- Remove the deck mould frames and stringer the hull mould
using the stringers from the deck mould.
- Fit the foam and glass the inside laminate to the hull.
- Make up the hull/deck flange on the
- Fit all the internal structure and furniture and paint
as required.
- Make up a temporary support frame for the deck and place
the 4 pieces on the hull
- Laminate the outside deck laminate including the hull/deck
joint.
- Turn the boat over and fair and laminate the hull outside.
- Fair and paint the hull outside while upside down.
Building
method 2 (2-3 boats)
Hull is built over
a male mould with vacum
The Deck is built over a female MDF mould with vacum.
Internals are built from fiberglass female moulds.
The foils, including bulb are built from female fiberglass
moulds with the bulb integral with the keel.
Building
method 2 (More than 3 boats)
Hull is built over
a male mould with vacum
The Deck is built over a female MDF mould with vacum.
Internals are built from fiberglass female moulds.
The foils, including bulb are built from female fiberglass
moulds with the bulb integral with the keel.
Frequently
asked Questions
How
much space do I need? - Our whole concept of building one boat is based on the
utilisation of minimum space. The hull and decks are built
from the same mould and the temporary mould is dismantled
around the boat when finished. So the dimensions of the
boat plus a bit of working space is all that required.
What special tools do I need? – For one-off boats, basic hand tools and fiberglass
handling tools is all that is required.
If you are setting up to build more than one boat a vacum
pump and maybe a wet-out machine will come in handy.
Where do I get building material? – Talk to your local boatbuilder first and fine out
where he gets his supplies. There are a number of very good
suppliers throughout the world. We can recommend several
that will supply a complete boat package at good rates if
required.
How
strong is the boat? – The design philosophy for amateur constructed boats
has a built in strength factor that allows for additional
strength in the critical parts of the boat that may not
be constructed to the high standard achieved by a commercial
boatbuilder.
Will
my wife approve? – Building boats is a family sport, get every one involved.
A family that plays together stays together.
How
do I know if I am doing a good job? – Work on the big brother concept, Get a friend or
even pay a boatbuilder that is knowledgeable to check your
work as the boat progresses. This way you never progress
to the next step before you are ready.
How
do I paint the boat? – Most of the undercoating can be done by roller, however
the finishing undercoats and top coats need to be applied
by a professional painter. We often hire a boat painter
or even an auto painter for the time it takes to spray the
boat with the sanding labour supplied by willing friends.
How
do I convert from metrics? –
Don’t, use the metric system if the boat is designed
in metrics, the system is much easier to use you will be
less prone to make mistakes. Get a metric tape and go for
it.
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What
our builders say
I have
built a number of Tboats now and find the techniques simple
and easy to use.
Andy
Turton (Boatbuilder AUS)
Jan Myslik (Sailor)
Jay Price (Amateur builder)
Brook Falconer (Amateur builder)
Phil Houghton (Sailmaker)
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