The Construction Process
Made Simple

Step Three
The Hull - Inside Layers

The hull is composed of layers of wood sandwiched around a foam core and covered in fiberglass cloth. Everything is glued together with epoxy mixed with various fiber fillers and strengtheners. The process is referred to as “composite” or “cold molded”.

The first layer of the boat’s composite hull is made of strips of cedar placed diagonally. Then, another layer of cedar strips are placed at right angles to the first.

These layers are all glued together with a process called “vacuum bagging”. The layer is covered with the epoxy mixture and then an outside layer of plastic. The two plastic layers are stuck together at the edges with special sticky putty-like tape. A vacuum hose is inserted, and the air pressure outside the bag squeezes the layers together and forms a tight bond.