21' Garvey flex - Material cost calculator
The material cost calculator
The material amount will vary depending on your skill level. The epoxy resin amount is with a 10% waste factor.
The requirements above are not a fully description of the grades but an abstract of the requirements.
One thing you must always remember is to buy plywood that are glued with water and boiling proof glue. That is normally stated with a WBP mark.
Most of the designs from Boatplans.dk do not require glass fabric on the entire hull. Basically it is a choice omitted because the fabric often makes the finish work more difficult. For most designs the strength of the plywood is more than enough for the boat.
It is however possible to cover the hull with a glass fabric in order to obtain better durability and easier maintenance over the years. If you choose so my advice will be to choose a crowfoot woven light fabric. Furthermore the crowfoot weave has the advantage that it is totally invisible when wetted out with resin.
For the designs that require glass fabric a biaxial ±45° glass fabric is chosen. The fabric consists of two layers of glass laid perpendicular to each other and in an angel of ±45° to to the warp direction. The two layers are stitched together.
The fabric gives an outstanding and strong laminate. Furthermore it is easy to work with and very flexible. It requires some finish work after it is wetted out and the laminate is dry, but when wetted out and rolled carefully the finish work can be kept at a minimum.
The glass tape specified can be of any regular available type. One thing that is important is that the tape you choose has a minimum weight as specified under the different designs. If your normal supplier does not have the weight specified choose the nearest weight above the one specified.
Epoxy resin for your new boat can be bought from many suppliers and manufactures. Choose the supplier where you get the best service and guidance, also if something turns out not exactly as you suspected.
You can get epoxy resin with different hardeners. Some are meant for slow cure and some for fast. If you can't find a hardener with a curing time that fits your need it is often possible to mix the hardener. This means that if you would like to have a gel time between the slow and fast hardener you simply mix the two and achieve a gel time in between.
Some manufactures produce a special tropic hardener. It is very suitable for laminating in warm areas. You will then have time to apply and work with the epoxy even if the temperature reaches 43°C (109F).
The amount of resin is, for the metric units, given in kg. Some suppliers give the amount in litres. As an approximation you can make 1 litre equal 1.1 kg. This means the other way around that 1 kg is equal 0.9 litres.
The filler is applied to the epoxy resin in order to make it thicker. The thickened epoxy resin is used for making fillets between the panels and the frames.
For most of our designs you can use ordinary wood flour. Basically the wood flour is some fine and very clean sawdust, and in principles you can make it yourself. But it is recommended to buy it from your supplier since you get a very clean product without any impurity.
For some of our designs the filler specified is Aerosil or Carbosil. It is important to use Aerosil or Cabosil because the fillet needs some structural properties that the filler will apply to the epoxy resin. Adding Aerosil or Cabosil to the epoxy makes it harder to grind, therefore the best thing to do is to smooth the fillets carefully before they harden.
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