19 foot Offshore Power Dory Build #7: Finishing the Fiberglass on the Boat

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Blog entry by English posted 02-27-2015 10:21 PM 5078 reads 0 times favorited 9 comments Add to Favorites Watch
« Part 6: Fairing the plywood for Fiberglass and First layer of Glass. Part 7 of 19 foot Offshore Power Dory Build series Part 8: Getting the boat ready for paint, Painting, flipping the boat over. »

I am at 180 hours on the build and the boat weighs 835 lbs.

Since my last update I have added another layer of fiberglass to the entire boat and 3 coats of epoxy filler. I had some issues with the epoxy fill coats, the epoxy I am using is 600cc viscosity. that’s very thin. It runs very badly . I discovered today after sanding off my runs from the 2nd coat, that if I used a 1/4” foam roller, I could roll it on thin enough that it did not run. It did leave a lot of bubbles in the epoxy. But I remembered something I read on a boat builder’s forum, that a hair dyer or heat gun would bust the bubbles. I was amazed at how quick and easy the bubbles disappeared. Just waving the gun over the epoxy at 10” from the surface and keeping it moving very fast took care of all the bubbles.

I do have a few runs on the transom but they will sand out easily tomorrow.

The second layer went on much like the first except I reversed the side on the bottom where the cloth overlapped to keep from having a ridge to have to fair.

After I wet out all of the second layer of fiberglass. I let it cure for two days then following a recommendation from Paul (shipwright), I sanded the epoxy that was sitting proud of the fiberglass weave smooth. This did away with the deep voids that would have taken a lot more epoxy to fill.

Here I am sanding off the epoxy. I am wearing the suit because I also am feathering the edges of the overlaps in the fiberglass. Also the epoxy is not finished curing. Uncured epoxy will finish curing where ever it is. In your eyes in your lungs. So I chose the suit and full face respirator for my safety.

Here is a close up of what I was sanding.

Here is what the boat looks like with 3 coats of epoxy fill. I only used 1/2 gallon of epoxy on all three coats.

Next I sand the epoxy smooth, Use System 3 Quick Fair to fill in any low spots, sand again then paint. I will update again after the paint job.

Thanks for looking.

-- John, Suffolk Virgina

9 comments so far

View shipwright's profile


8452 posts in 3402 days

#1 posted 02-28-2015 12:09 AM

I think I’ve said it before here but …. Boy, these pictures look familiar!
Looks like you are doing everything spot on right John.

Good work.

BTW, the fit in your shop looks a bit tighter than mine was.

-- Paul M ..............the early bird may get the worm but it’s the second mouse that gets the cheese!

View johnstoneb's profile


3131 posts in 2777 days

#2 posted 02-28-2015 01:00 AM

That glass looks good.

-- Bruce, Boise, ID

View grizzman's profile


7836 posts in 3908 days

#3 posted 02-28-2015 03:20 AM

i cant believe you would show FRIENDSHIP in her underwear….lol…she might be embarrassed..i love watching the builds on this boat, good work, your boat will be in the water before you know it…and you will smile ear to ear, thanks for taking us along….

-- GRIZZMAN ...[''''']

View lightweightladylefty's profile


3470 posts in 4317 days

#4 posted 02-28-2015 06:15 AM


Your boat is really taking shape! I’m enjoying your blog.


-- Jesus is the ONLY reason for ANY season.

View changeoffocus's profile


467 posts in 2221 days

#5 posted 03-02-2015 01:12 AM

It’s really taking shape and it’s fun reading about Paul’s helping you through the rough spots.
It will interesting to see how you turn this over. I have noticed the shop is getting much smaller.

View English's profile


682 posts in 2081 days

#6 posted 03-02-2015 01:11 PM

Bob the flip will be tough. I plan to move it outside. I hope to get about ten neighbors to help. If I can’ t get enough help I will build a ganty crane over it outside and use a hoist.

The size of the shop is what determined the size of the boat I could build. If I had more room I would have built a 24- 27 footer.

-- John, Suffolk Virgina

View changeoffocus's profile


467 posts in 2221 days

#7 posted 03-02-2015 08:46 PM

Like Paul telling you that you needed a plane
I respectfully suggest you get a commercial crane.
I’ve not had experience in rigging boats but I’m sure Paul will give you guidance on sling placement and cross supports or he may have trick for doing it another way.
I would hate to see all that beautiful worked damaged.
Those small cranes are very reasonable.

View English's profile


682 posts in 2081 days

#8 posted 03-02-2015 09:39 PM


I’ve done a good bit of research on the flip. I plan to build a cradle around the boat similar to this.

While it is in the cradle upside down I plan to remove the legs from the strong-back that it’s on now in my shop.

I hope at this point that I can get enough help from my neighbors to lift it up and flip it onto it’s side. Then with a rope connected to my truck control the last 90 degrees to the ground. If I can’t get enough help. I will then build a gantry similar to this and use two chain hoists connected to the cradle.

-- John, Suffolk Virgina

View changeoffocus's profile


467 posts in 2221 days

#9 posted 03-03-2015 12:55 AM

Ingenuity in action, you and David Mitchell (Patron) sure know how to improvise.
Please do share pictures on the flip.

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