A while back, as I was waiting in the reception lobby of a major American corporation, I had the chance to admire the curved reception desk and other oak furniture in the room. However, when I examined the reception desk more closely, I could see facets in the oak veneer instead of a nice, smooth curve. I immediately realized that the cabinet builders had sawn closely spaced saw kerfs in the back of the panel so they could bend it to shape. I thought there must be a better way.
The following is a description of “the better way” — the methods of building expert Jon Staudacher, to create curved walls and curved face cabinets. Jon’s boat and airplane building background, coupled with the unique properties of WEST SYSTEM® epoxy, have combined to create very elegant solutions to difficult construction problems. Continue reading →
In midwinter, we purchased a portable barbecue and would, by summer, need some kind of table to support it. The table was to be located in an old English garden setting. We wanted a compact, all-weather structure that could be permanently affixed just off the edge of a patio, blend into the surroundings, complement a nearby picnic table, conceal a 20 lb LP gas container, and outlast a long succession of barbecue grills.
Our table design was completed by early spring. Retired Gougeon technical advisor, Brian Knight, agreed to build it as an example of high-quality, all-weather construction using treated lumber and WEST SYSTEM® epoxy. Continue reading →
Cover Photo: The finished 24′ front columns built by Pleasant Bay Boat & Spar Company.
Pleasant Bay Boat and Spar Company is a boat building and spar fabrication shop located in Orleans on beautiful Cape Cod. We have been building, restoring and repairing boats on the Cape since 1999.
Shortly after I set up shop, I began making spars and created a niche for the business. With a lot of help and advice along the way, I developed an efficient system to make hollow “bird’s mouth” poles that were turned into masts, booms and gaffs for sailboats, and flagpoles. The machinery didn’t know the difference. Working with boat builders and designers pushed us to go further. The crew expanded to include Doug Ingram, our full time spar maker. The masts got longer and more complicated. Flagpoles were shipped as far away as Bermuda or installed on the facade of the Federal Reserve Bank in New York. Our reputation grew exponentially with the level of experience. Continue reading →
I don’t know about you, but I have problems finding wastebaskets that fit the spaces I have in mind. The baskets are either way too small or a bit too large for the opening. It happened at a previous house we lived in and it happened again in our current home. My solution was to make my own baskets with 4 to 6mm (3 16″ to 1 4″ thick) plywood sealed with and glued together with WEST SYSTEM® Epoxy. Continue reading →
There are often interesting articles in Epoxyworks magazine illustrating the different uses of the WEST SYSTEM epoxy. I admire the time and effort that goes into some of these handmade boats that are like art projects. But in my particular situation, I was most concerned about strength rather than the aesthetics. I was dealing with wood rot at the bases of the support posts for a large patio deck. There are two levels on this deck, with the patio furniture on the top level and a built-in hot tub in the lower level. The deck is constructed of 6×6 support posts, 2×12 flooring supports and 2×4s for the finished floor. All of this is redwood. Continue reading →
Those working on projects that use epoxy for restoration and rot repair often ask, “How long will this last? Will the rot return?” At Gougeon Brothers, Inc., we have lots of in-house test approaches that can analyze tension, compression, shear, and fatigue. We can also predict the consequences of ultra-violet, arid, tropical, and cold conditions. Still, there’s nothing like real-world performance over time. Continue reading →
At the end of moving day, after many large items had passed through the doorway, our house’s steel door was left with a nasty crease about a foot long. The door had a foam core. The needed repair was just a fairing application with no structural component. Continue reading →
My wife gave me the basic guidelines for a planter box she wanted me to build. First, keep it cheap. Second, she wanted an “L” shape. Third, she provided some rough dimensions. The design was up to me. Logic seems to abandon me when I design something, and this project was no exception. A nice, straightforward box with square corners should have been the default. But after some doodling on paper, I decided to build a planter with flared sides and rounded corners. Continue reading →
Pouring a thick coating of epoxy onto a table top can produce a unique effect. With a ¼” thick coating, you can cast a variety of objects in the epoxy for decorative accents. Coins, fabrics, sticks of wood, memorabilia and photographs have been used in this decoupage application. Here are a few tricks to make things go more smoothly. Continue reading →
A 100 year-old friend called in tears because her living room ceiling had cracked and she was afraid that the ceiling was going to fall. I did my best to calm her and offered to come over and take a quick look. Continue reading →