Cold-Molded Composite Hull
The boat was built by Kevin Williams, with consultations from Bruce Roberts Inc, the Ontario Boat Builders Society (now defunct), and the Marine Surveyor Company of Bickers & Associates, represented by Surveyor Mr. Joe Trudeau. The hull was cold molded to Lloyds specifications, using the West Marine Epoxy Saturation Method. This West System epoxy cold molded process, involved 3 alternate layers of 12” wide strips of 1/4" marine mahogany plywood saturated in epoxy/resin with complete encapsulation. This is bonded to a kiln dried B.C. fir frame and stringer system. All materials were given 3 coats of Epoxy after fit and prior to bonding, as per West specifications. Hull exterior has 2 layers of 10oz fiberglass cloth primered and coated with International Paints polyurethane finish, comparable to a gel coated hull.
Decks, cabin roof, and bridge deck are all constructed of ½” mahogany marine ply over 1 ¾” x 3” clear fir beams @ 16” centers. All materials again given West System treatment and covered with one layer of fiberglass cloth with finish same as hull. All deck and rear cockpit areas have a non-skid finish. All resin used throughout the entire process was West’s Epoxy Resin. All inside corners are filleted and all outside corners radiused. The hull thickness varies between 7/8” -1” and is a strong structure.
The vessel has all decks, overheads, and all sidewalls in main cabin insulated with a 3” water-resistant fiberglass insulation for heat and cold. All fasteners used throughout the boat are stainless, with the exception of hull framework, where all high-strength silicone bronze was used. All exterior cleats, chocks, fittings, deck plates, railings, ladders, and hatch trims/hardware are all stainless. All windows on the boat are tinted tempered glass, with frames being marine anodized aluminum. The 3 deck hatches are Bomar Offshore 20” x 20” openings and aluminum frames. All fittings and hardware on the boat are either manufactured by brand name Marine companies or subcontracted out to Marine build shops.
The keel is of laminated solid Fir planks, through-bolted to a keelson of the same material with stainless steel through-bolts. A flush deck forward is FRP sealed. From amidships aft, high, hollow bulwarks are FRP covered and supported outboard on an epoxy coated Fir shelf. Painted steel posts sit of fir floors and support solid joists under the fir plywood soles. An FRP bow thruster tube is made entirely of chopped strand mat and bonded to the hull.
Most of the major mechanical work and electronic gear setup was done by Butler Marine. The bilges and engine room are remarkably dry, well lit, and spacious.
Many yards in the U.S. are building using this cold-molded method. To mention a few: Rybovich, American Custom Yachts, Buddy Davis, Jarrett Bay, etc.. All very respected major offshore sports fishing lines that take a real beating out in the open ocean. These vessels are subjected to harsh seas and use the cold molded process - and for good reason. They are strong, long lasting, better softer riding and not subject to the negatives of the fiberglass molded issues (blistering, delamination, hard riding, weight, etc.).
Below is a reproduced off the web site of Gougeon Brothers
EPOXY COMPOSITE CONSTRUCTION
Twenty-five years of advances in construction techniques using epoxy-bonded materials have revolutionized boatbuilding and set new standards for performance and reliability. Leading builders are building stronger, lighter, more durable boats with epoxy composite construction.
WHAT IS EPOXY COMPOSITE CONSTRUCTION?
Epoxy composite construction consists of bonding all of the materials and parts of the boat together with epoxy resin. The resulting structure has physical characteristics superior to the components by themselves. Composite construction includes a variety of building methods that use epoxy to protect the materials from moisture as well as hold the materials together. Epoxy resins, the key ingredient, are among the most versatile of thermoset plastics. They bond exceptionally well to a wide range of materials and are highly moisture resistant. Compared to polyester resins typically used in fiberglass boat construction, epoxies have greater st4ength, less shrinkage, better moisture resistance and better fatigue resistance.
WHAT ARE THE ADVANTAGES?
Versatility: The builder using composite technology can build boats with a range of materials, designs and construction methods that are perfectly suited to the boat’s use and the customer’s needs. Everything from strip canoes to work boats, high performance multihulls to offshore racing powerboats have been built using epoxy composite construction.
Lower Maintenance: All of the components in a composite boat are protected by an epoxy moisture barrier. Since the moisture content is stabilized, the maintenance problems associated with wooden boats – rot, joint cracks, structural members swelling or shrinking, and surface checking – are eliminated.
A History of Success: Epoxy composite construction techniques for boatbuilding were first developed over thirty years ago. Over the years, thousands of composite recreational and working boats have been built and the earliest are still going strong. Composite construction has proved itself at the top levels of competition in sail and powerboat racing, in the harshest environments and under the toughest working conditions.