The Construction Process
Made Simple

The core is sanded smooth by hand with three people and a
9-foot sanding board called a “longboard”. This “longboard” is pushed across the hull to smooth out the curves.

Once smooth, the outside layer of the sandwich is applied. It is composed of cedar strips laid at 45° angles and “vacuum

bagged” just like the inner layer. These layers are sanded until fair with the “longboard”.

For additional strength at the bow above the waterline back to mid-ship, there is a layer of Kevlar cloth (similar to bullet proof vest material) epoxied to the outside of the hull for impact strength.

The entire outside of the hull is then encased in two layers of 6-ounce fiberglass cloth. From the waterline down another two layers of cloth are applied totaling 4 layers of fiberglass under water. The epoxy forms a permanent water barrier.

The hull is sanded and sprayed with a primer called “Duratec”. The primer is “longboarded” until smooth and then sprayed again.