I temp mounted the upper sides and marked out windows and windshield's. i built them out of 1/2" just need to cut the holes and glass, and order some windows.
Would you glass before or after cutting?
On a side note I got a call from the Mercury dealer, I placed the order sometime in January and was told almost a year wait, but it came in. Than makes me happy!
Great news on the motor! It motor-vates you to get the boat in the water too!
I always glass flat pieces before they go into the boat, and fair-in the seams after they're built (taper the edges of glass tape with a carbide scraper, flat/straight blade). The less glassing you do inside the boat, the better ... which means 'the easier' and 'no glassing of vertical plywood'. On plywood that will be curved when installed, you can only glass the inside of the curve, e.g. the inside of the boat side. Putting glass on the convex side makes the plywood too stiff, but works just fine on the concave side of the bend. Finally, for pieces that get holes cut out, like the sections of the windshield, I glass first, then mark and cut out the holes later .... and when they're the final size, seal the plywood edges inside the hole: Slightly round over the edges of the cut-out, brush or roll plain epoxy into the end grain until it remains shiny even after 10-15 minutes, then let cure. Hand sand all, wipe with wet cloth to clean well, then smear silica-thickened epoxy into all the end grain leaving a smooth white coat. The first step above wicks epoxy into the wood cells. The second step fills all micro-details in the wood and leaves it smooth and ready for final epoxy coats. When you apply the final epoxy coats to those pieces, just roll the epoxy onto the edges of the hole while you're at it, and clean up any drips with a swipe of a foam brush.
Brian
Brian
