"AYE DOCK" Boat Build

The project started with one really big piece of tracing paper and a full size set of plans.

I cut through two sheets of marine plywood at the same time so both sides would match. This was the concept the plans led me to believe.

Once encapsulated with epoxy resin they were all butt glued together. It still dosen't look like a boat. I am now committed at this point and my wife seems to have some doubts. (I have never done this before.)

I placed the floor of the boat on some elevated stands. This was so l could get underneath to stitch it together. At this point my wife was thinking I had lost it.

Let me introduce Keith. You have to have a VERY good friend and partner in crime to pull this off. I think Keith was having some doubts at this point because he had never built a boat before either.

It actually worked. Both sides came together just like the plans said they would. I was glad Keith was around or it would never have happened. Diane wasn't sure this would be a boat she would want go out in.

One central rib was used to bend the plywood around so the shape of the boat would be symmetrical. The stern section was added with some difficulty but finally fit. Now it was starting to look like a boat. Held together with a prayer and MANY copper stitches. We next leveled and squared up the stern and sides.

Now I spread a fillit material of epoxy resin, micro spheres and silica between the stitches. Diane still had her doubts.

A second spread of epoxy was added to cover the stitches. Now the copper stitches were removed and a fiberglass cloth covering was added. For the first time I was beginning to think this might work. Diane wasn't sure.

Interior frame work for the bow area was held into place with epoxy and fiberglass. The interior work would give the boat strength so ribbing was not needed. The plans said so. I believed them and move ahead. Diane wasn't sure.

I had to design the stern section. This was not in the plans and the boat needed more seating if we were to have friends aboard for sunset cruses. Diane was thinking it might work maybe.

I added foam flotation to the bow section. This was not in the plans but thought it might me a good idea. This Diane did agree with.

I changed the seat sections from the plans to allow more leg room and gave them a Sapele Mahogany trim. I thought it looked good and gave more support to the design.

The bow section interior is now complete and it was time to start on the stern section.

The stern seat sections were given the same treatment. I decided to go ahead and paint the interior seat compartments thinking it would be easier to do now.

The interior is finished and it does look like a boat is taking shape. For the first time Diane is thinking I might pull this off. In my mind I am wondering if the whole thing would collapse when we rolled it over on its side to turn it over.

I got my son-in-law with three of his weight lifting friends to move the boat off the stands. Another set of stands were made to place the boat upside down on to finish the hull.

Would you believe it worked and the boat did not collapse. All went well. I was a wreck worrying about it. Diane was happy.

Now all the open seams had to be filled with the fillit material and sanded. Actually I sanded and sanded and sanded with my little Ryobi 5 inch orbital sander.

When the fililt material was smooth two types of fiberglass cloth were cut to be epoxied over the seams.

More fillit material was applied to smooth out the fiberglass seams. More sanding and sanding and sanding. Diane was getting tired of the dust and her car was outside. She had no idea how much more sanding was to come.

Yet another spread of fillit material was applied and sanded again to finally make the hull smooth.

Keith and I had never fiberglassed this much material before. We were committed. We placed on our breathers and went to work as a team.

Keith mixed the epoxy and I spread it with a roller. It actually went easier than we had expected.

Would you believe we finished in about two hours and it looked great. Diane by the way left for the day.

All the fittings came in form Glen L marine in California. I purchased the Lo Volt plans from them and posted on a forum so others around the world could give advice on the build. It was about this time I spoke with Mr Whitt the Navel architect who designed the boat. This particular design of the boat had never built before. He assured me it would float and others around the world were now watching.

The rudder was cast for the boat at the Glen L foundry. Glen L was also working on the strut since it had to be made also. This is the mock up of the keel section. I made an exact duplicate of the boat to make practice holes and figure things out before committing to the actual boat.

The strut came in and was positioned in place on the mock up. Now I was ready to design the electric motor hook up to the shaft.

After considerable research a plan eventually developed in my mind as to how it would work. These are my drawings for Jim to make the motor mount with a belt to act as a V drive.