FastBrick

Tender/Lifeboat, Page 6

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With the bottom foam installed, the 1/8" ply flooring was glued in over it.  In order to get good pressure on the plywood to put it in contact with the foam, more creative clamping was devised.  Water and fuel jugs are excellent for this purpose because they have good heft when full, and handles to place them.  Steel crates full of heavy fasteners and paint cans also work well.

 

After the flooring is in, the side foam gets glued in.  I found that it's important to keep the sides from dishing, so a 2x4 was clamped edge-on to the side rail to help keep the side panel straight under the pressure of the shoring.

 

With all the side foam in place, the side interior sheathing goes in the same way the foam did, with lots of shores to get pressure distributed over the panel for a good glue up.  That's a Michalak Toto double paddle canoe going together on the assembly table next to the FastBrick.  The interior foam and panels take up a lot of clamps and interfere with access to most of the interior while the epoxy is curing, so having a small simple project to work on while the glue cures is one way to make use of the available time.

 

The completed interior paneling, ready for filleting and other finish work.  The watertight hatch cutout has been cut and routed out, and the bow locker top has been installed after drilling the bow transom for the twin eyebolts that will serve as bow eyes.

 

Here's a close-up of the forefoot hatch cutout showing the framing and foam filling to make the hatch flush with the top surface of the flooring.  Polyurethane insulation foam was sprayed into the gaps between the hatch framing and the Styrofoam, then trimmed with a big knife after it cured.  It's important to make sure that the folding grapnel anchor that stows in this space will fit through the hatch if you do it this way.

 

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