Building the "Swiss Army Knife" of Small Boats...Wood Duck Double #22: Applying Second Coat of Epoxy to Hull

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Blog entry by DustyMark posted 07-12-2020 03:19 AM 572 reads 0 times favorited 0 comments Add to Favorites Watch
« Part 21: Fiberglassing the Hull Part 22 of Building the "Swiss Army Knife" of Small Boats...Wood Duck Double series Part 23: Fiberglassing the Deck »

Prep Work

The epoxy is only green cured and it’s pretty easy to trim off the excess fiberglass with a razor.

Oops! I trimmed a little bit into the wood here. No problem, it will get epoxy over it.

Here’s a close-up of the weave after the first coat.

Applying Second Coat
The fiberglass takes way less epoxy on the second coat. I use the same techniques as on the first coat. Squeegeeing the epoxy well will cut down on your sanding later.

Here’s the weave after the second coat of epoxy. Four-ounce cloth doesn’t have a real aggressive weave. I’m satisfied with this level of fill for my “utility build” and won’t apply a third coat of epoxy to further fill the weave.

Hatch Cover Stiffeners
The hatch covers are pretty thin and need a piece of plywood to stiffen them up.

Here’s a hatch and its stiffener. NOTE: The thicker plywood underneath is not part of the hatch…it’s simply a clamping base to ensure the hatch cover remains straight during clamping. I failed to do this when building a skeg box on my wife’s kayak and it has a permanent/troublesome twist in it…forever!

This hatch cover is epoxied and ready for clamping.

Both hatch cover stiffeners epoxied and clamped. They’ll be cured enough to remove the clamps in the morning and fiberglass the hatch covers at the same time I fiberglass the deck.

Fiberglass the deck.

-- Mark, Minnesota

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