Fiberglass and Foam Lay-up

After making the mold modifications needed to vacuum bag and infuse the resin, we’re now cutting out the templates to be used for cutting the foam and the fibreglass. We chose Triax 20 ounce fibreglass and one-half inch Baltek Airex for foam core. These were chosen to build the stiffest sabot possible that would still weigh-in under 95 pounds.

Use of square and batten to create templates

Use of square and batten to create templates

With each template cut, we test-fit to be sure they will work together. These shown below are for foam core cut-outs.

Test fitting of templates

Test fitting of templates

Pretty simple – cut each ‘glass sheet from the final templates…

Using transom template to cut fibreglass

Using transom template to cut fibreglass

And again, each sheet is test-fit in the mold. The templates are made to give the fibreglass 2-3 inches of overlap. Darts are also cut to be sure if easily fits flat against the mold.

Fitting of bottom fibreglass

Fitting of bottom fibreglass

Fitting of the bow ‘glass to the mold.

Fibreglass cut for bottom and bow

Fibreglass cut for bottom and bow

Now, all fibreglass is laid-up with sufficient overlap onto the top flange to ensure the resin infusion is well over the boat itself. (yes, lots of waxing on the flange needed to not have it stick!)

All 'glass components fit to mold

All ‘glass components fit to mold

Now we can begin fitting the foam components…

Fitting of bottom and transom foam

Fitting of bottom and transom foam

Once all the foam is fit, we can begin to add the top layers of fiberglass. Extra strips added to the center foam joints.

Foam and center class layup

Foam and center glass lay-up

Tomorrow we complete the lay-up and begin the bagging process.