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AFter the fibers are laid, the infusion disposables are next: Peel ply, infusion mesh, resin feed lines, vacuum lines, and finally the vacuum bag. Peel ply is a nylon cloth that allows everything else to release from the epoxy. The green stuff I'm using is silicone coated to release easier...

Yep- Once I open the resin line, I expect everything to wet out in 30-40 minutes. This is a cut section of my gunnel infusion test- both sides wet out fine. The gunnels are the last thing in the flow path though, so it will be slow to infuse. If there is a problem with the infusion not wetting...

Same materials, different application. Hopefully similar velocities :) Not sure exactly. I had a test piece measure real close to 1.1mm, but it used a thicker twill carbon. I have about $80 in the plug (waste), $450 in the mold (reusable), and $1100 in the infusion (materials and...

Lots of work completed this weekend: I laid up all the dry fiber. First, the full blanket of innegra/carbon hybrid. Then, a blanket of plain weave innegra. It was much more difficult than I would have thought to get everything to lay down flat without wrinkles. I used some 3M super77 spray...

For all my test infusions I made a spreadsheet to keep track of fabric size/weight/sq in of core/resin usage and final part weight. Every test I would calculate the fiber volume ratio and tweak the spreadsheet to match better. So I have a pretty good estimation of how much epoxy to infuse. It...

The carbon/Kevlar sleeve I’m using is 5.7oz cloth. The carbon sleeve is 7oz- so with my three layers, it’s near the same fiber weight as yours! Looking at total fiber weight was how I started estimating what layup schedule to use for my hull. Most commercial manufacturers and other builds...

I assembled both halves of the mold and bolted them together. Then I constructed two slings on the strongback to hold the upright mold: these are simply 2x4's screwed to the strongback in a "v" fashion with an NRS strap slung between the tops of the v to cradle the mold. It is resting about...

Final mold prep here. On one of my test infusions, the very last part to infuse was the underside fo the gunnel, and there was even a small dry spot. I suspect that this was due to temperature: the bottom of the gunnel was the only place hiding from the infrared tube heater. It was the last part...

Problem: I had planned on wrapping the gunwales with a carbon/Kevlar braided sleeve. I like the combo of stiff carbon and resilient kevlar. Soller composites will dye the Kevlar for you and I ordered black. I just unwrapped it today and noticed that the kevlar has a distinct shade of green. I...

Thanks! that's good info. I have real limited experience with rudders- and never in a canoe. It's another one of the unknown variables with this project. I know already I don't like the weight of it. I plan to keep it out of the water for straight line/calm paddling and avoid the extra...

Ribs are cut and molded from the scrim/scored 1/4" divynicell. First, I located a rib at each mounting point for the foot pegs, then I worked out that I could evenly space remaining ribs fore/aft at about 27" apart. This ended up being a total of 8 each side. My test panel (rib edges chamfered...

I like the plan of sanding it down (including the old patch) and coating with a layer or two of epoxy: it should bond to the existing fiberglass pretty well and give a new finish. It’s probably easier to apply/sand than a polyester Gelcoat. It won’t add any structural benefit: if you need...

Yes, the seat has a build thread of its own. You'll recognize the design as something else Alan came up with. A part of my mold making and infusion practice was making the seat and pedestal. It is meant to leave enough room on the sides to kneel for a bit when my bottom gets sore from sitting...

Yep, on my test I chamfered the edges at a 45deg angle. I’d like to go shallower but will have to work out how. My bandsaw table will only tilt to 45. Maybe the answer is a sanding block and some 60grit!

I still have to polish the mold, but I thought I'd get started on the gunwales. It's a milestone because it is the first time I am working on something that will be part of the final boat. The gunwale profile I successfully tested is an "L" shape that sits on the top edge of the mold. I...

I went about dismantling the plug this evening. First, I unscrewed it from the strongback and laid it down in the grass. Then, with some help from a hammer, I was able to remove the forms and keep the shell mostly intact. It 's somewhat floppy, and it cracked and groaned when I sat in it, but...

Some good news, and some not as good news: Good news: I'm finished fiberglassing. And happy about it. Good news: The mold released just fine from the plug, and has a great shiny tool surface. Not as good news: Im going to have to do a little repair on the mold. I finished laminating the...

Yes. The canoe has inherent stiffness in a bow/stern direction just because of its shape. The weaker axis is side-to-side: so things like ribs/core-floor construction try to stiffen this axis to prevent oil-canning. So make sure at least some fibers are oriented running side-to-side. So any...

Yes, I wear it when spraying gelcoat or pva or anything. When laminating, though, I just wear safety glasses, but not the respirator. I do have exhaust fans running that can do 1.5 volume changes/minute. It keeps the air fresh enough. I had thought about that, but didn't want to invest in...

I finished one half of the mold and pulled the parting dam to get ready to gelcoat the other half. The packing tape withe the wax/pva treatment separated really well. The clay didn't damage the other side of the waxed plug, and came off cleanly. One of the unanswered questions I had was...