Fiberglassing: the skin of the boat

After we finished the wood repairs, it was time for the "exoskeleton" of the boat - its fiberglass skin.  Fiberglass comes as a cloth that can be cut with scissors, full of fibers that are bonded together when resin is added. We bought 30 yards of cloth (3 feet wide) for the job! 

Why so much? Above the waterline, we used two layers of fiberglass, whereas below the water, we used between three and five layers. Each layer needs to be cut at increasing sizes so there is overlap and no "edge".

Doing flat sections like the port ama (side of the hull) was hard enough. The transoms took a lot of brain damage, until we figured out that we simply could not figure it out. Then we just decided to cut the cloth as we laid it on. Ed and Pat show off our attempts to "cut to fit" using tape to hold it in place.

Feeding the crew lunch. Delicious burritos courtesy of executive chef Alyssum.

After applying epoxy resin and multiple layers of cloth, the wood is sealed off and the skin is really tough. Many trimarans were built in this way (fiberglass over plywood) because it avoids the complications of a wood plank boat (by sealing the wood from the water), and is a lot cheaper (and lighter) than an all fiberglass boat.

The big downside is that resin used for fiberglassing is fairly toxic - certainly not eco friendly. However, it will last a really long time, if taken care of properly, which can justify the process.  It is like drinking water out of stainless steel bottles instead of plastic disposable bottles - although the stainless steel takes a lot of energy to produce, if it is kept long enough, it far offsets the problems of disposable plastic. The trick is to keep the boat healthy (no delaminations or rot) so that the fiberglass can stay on for decades.

The crew at the end of the day... Ed, Trout, Jonathan, Sequoia, Dee, Alyssum, and Kristian.