Tag Archives: 20

Installing a Teak Deck on ZATARA

by Ken Newell

Epoxyworks 20

Cover Photo: The intricate plank layout of ZATARA’s finished teak-covered cockpit, before the hardware was reinstalled.

The Zatara refit project began two years ago when my partner Steve Gallo (a mortgage banker) and myself, Ken Newell (a materials engineer), decided that we wanted something to do with our spare time and money. What we didn’t realize was the level to which the refit project would absorb every weekend and every non-critical dollar we had and cause our significant others to chastise us for our obsessive behavior. Continue reading

Creating a Non-Skid Deck

By Bruce Niederer

This racing season onboard Triple Threat has been filled with the usual mix of tedium, laughs, and excitement. It’s a good thing when the exciting part is due to close racing and fast downwind surfing-it’s a bad thing if the excitement occurs when the foredeck crew nearly goes overboard because the deck is wet and the non-skid has the texture of a slip n’ slide! I’m happy to report no instances of skidding off the foredeck this year, as there had been in years past, because this year the non-skid was brand new. Continue reading

Avoiding Surface Contamination

By Brian Knight

“Cleanliness is next to Godliness” the old expression goes. This is certainly true when preparing a surface for an epoxy application. The surface has to be clean to begin with or there may be adhesion problems. But often, our good intentions with respect to cleaning a surface result in contaminates deposited on the surface. Below are some potential surface contaminates, ways to avoid them, and an almost foolproof method to determine if a surface is clean or contaminated. Continue reading

Wood/Epoxy Sump Cover

Richard Jobe was faced with having a sump located in the middle of a prominent landscaped area in front of his Newburgh, Indiana home. His solution was to build a cover (middle) for the sump that would be light enough for one person to handle, strong enough to hold the weight of half a foot of pea stone, and water resistant enough to survive being buried underground. Continue reading

Emergency Pump Repair

Barry Bew, a sailing instructor at Arethusa Venture Centre, Gravesend, Kent, UK, used his experience as a plant engineer to make an emergency repair to a swimming pool circulating pump. The pump was leaking at joints between the 3″ ABS plastic inlet and discharge pipes and the cast iron pump body. Continue reading

Installing a Bow Thruster

Island Heights, New Jersey architect, John B. Wilson, installed a bow thruster in his 26′ Albermarle sport fisherman, using WEST SYSTEM® products. The toughest part of the job was cutting through the 1″ solid hull laminate. After trying several tools, he had success with a Roto Zip™ with a ½” carbide bit by making two ½” deep passes. The only other difficult job was cutting away a portion of the floor in the storage area under the V-berth to make room for the 5″ diameter thrust tube. Continue reading

Building Alligator

BY BOB WALTERS

About ten years ago my wife, Ching, and I decided we wanted a comfortable, easy-to-handle, cruising boat suitable for exploring the shallow coastal areas that we missed when we lived aboard our deep draft sailboat twenty-one years ago. We looked at a lot of boats and decided that we would try a powerboat this time. We liked the features found on Biloxi Luggers, also known as “Chandeleur Boats,” a type indigenous to the upper Gulf Coast; however, we didn’t want to own a 30-50 year old wooden boat. Luggers aren’t available as production boats and we couldn’t afford to commission a custom design, so we decided to build Alligator ourselves. Continue reading

Testing DCPD Blend Laminates

By Tom Pawlak

Gougeon Brothers recently did R&D testing for a manufacturer who wanted to know if WEST SYSTEM® epoxy could effectively repair injection-molded parts made with fiberglass and dicyclopentadiene (DCPD) blended polyester resin that included an internal mold release. The hoods and decks for many jet skis and snowmobiles are made with this material.

DCPD blends in polyester cause it to cure rapidly and cross-link thoroughly. This feature helps to reduce emissions from the resin but makes it difficult to repair Continue reading

Replacing Damaged Bulkheads

By Dan Witucki

The port bulkhead with the chainplate still attached.

If you race a sailboat long and hard enough, it eventually will reveal its weaknesses, sometimes violently. My friends and I race an Evelyn 32-2 called Rush. Less than a month before the 2002 Mackinaw races, we were competing in the Saginaw Bay Yacht Racing Association, Gravelly Shoals race. Throughout the race the wind had been building and we were a little overpowered with a full main and 150% head sail. We had completed about 45 miles of the 50-mile race when the starboard chainplate decided it had enough and pulled out of the bulkhead. Continue reading

G/5 Adhesive Tips

By Tom Pawlak

Many of us at Gougeon Brothers experiment with WEST SYSTEM® products on personal projects at home as well as at work. We often push products and techniques beyond the limits recommended in our literature. Sometimes the experiment fails, sometimes we discover something very useful. Continue reading