Epoxy Fillers, Fillets and Finishing. | Minimize your sanding - Free Range Boat Build stage 7.

Discover how you can significantly reduce the time spent sanding your boat during the build process with expert advice on using epoxy fillers, fillets, and finishing techniques. Join us in this exciting episode of Free Range Boat Build as we progress to stage 7!

Epoxy Fillers, Fillets, and Finishing

In the previous episode, we successfully embedded the lead ingot that would provide ballast into the boat’s centerboard using a template and router. The resulting close fit ensured the lead could be held firmly in place with a few 3/4-inch screws on one side.

To enhance adhesion, a bit more glue powder was used than usual to prevent it from running too far into the gap when gluing from the other side. This allowed the epoxy to fill and bind the space between the ingot and timber efficiently.

Stern Cap Shaping

While the epoxy cured, the opportunity arose to shape the stern cap for the transom. An initial template was cut from existing MDF templates, followed by Roy Obasa closely following the curves.

Ply Template Precision

To ensure a stronger fit for two pieces of timber, an additional ply template was created. The edges were then rounded on the router table to prevent future paint failures.

Rapid Curing in Warm Weather

In the warm weather, the resin cured quickly, and we were soon ready to move on to the next step.

Filler Sanding Made Easy

The use of leftover sawdust from previous sanding and routing provided a serviceable extender for filling and forming fillets. To create a smoother finish, a slightly wetter mix was used for filling holes.

Fillet Formation with Wood Dust

A mixture of wood dust was incorporated into the filler to provide a bulkier, coarser product for easy sanding. This technique reduced the need for extensive hand sanding while ensuring a smooth finish.

Navigating Sharp Transitions

To prevent fiberglass issues, it was essential to create smooth transitions around sharp corners in the fillet. This required careful attention and polishing using methylated spirits for a glossy finish.

Diamond Tip Tool for Resin Removal

In the past, a diamond-tip tool for dealing with excess resin had proven invaluable. This tool was used to remove bulged-out resin and create even transitions between timber and epoxy.

Making Quick Work of Fillet Sanding

A multitool with a diamond-tip attachment made short work of sanding the hard resin areas, reducing time and effort compared to traditional sandpaper methods.

The Finer Details

A mix of finer dust was used for final sanding, ensuring a smooth finish while preserving the overall shape and integrity of the timber.

Straightforward Groove Cutting

To create a lifting point on the centerboard, a straightforward groove was cut using a 6mm drill bit. This ensured precise alignment and a smooth finish.

Curated Tools for Efficient Work

A combination of quality sandpaper and multitools helped streamline the boat building process, resulting in a smoother finish and fewer hassles during fiberglassing.

The Future Lifting Point

To facilitate lifting the centerboard easily, a lifting point was planned using dynema, a strong and lightweight material known for its abrasion resistance. This solution provided both functionality and efficiency.

In conclusion, by employing various epoxy fillers, fillets, and finishing techniques during stage 7 of the Free Range Boat Build, we successfully minimized sanding while maintaining a high-quality finish. By using the right tools and materials, such as multitools, sandpaper, and dynema, we ensured that each step was completed efficiently.

Multitool Tip: Diamond-Tip Attachment

The multitool with a diamond-tip attachment proved particularly useful in this episode. If you’re dealing with hard-to-sand areas or need to remove excess resin, consider incorporating this tool into your boat building toolkit.

Troubleshooting Sharp Corners

To ensure a seamless finish when fiberglassing, be mindful of sharp transitions in your boat build. Use methylated spirits to create a smooth surface and prevent issues during the fiberglass application process.

Incorporate Filler Wisely

To streamline your boat building process, be strategic when incorporating filler into your work. Using a mix of coarse and finer dust can help achieve the desired finish while minimizing the need for extensive hand sanding.

Streamlining Your Boat Build Process

Throughout this episode, we demonstrated how to streamline the boat building process by selecting the right tools and materials. By doing so, you can focus on other essential aspects of your project without wasting time on inefficient techniques or methods.

Looking Ahead

In our next episode, we’ll be moving forward with the fiberglassing process. Stay tuned to see how we apply resin and fiberglass to create a seamless finish on our boat build!