"Morgan" 15' 9" x 5' x 2" Beam  Dory Skiff
Designed and Drawn by Rob Hewitt
Built by Dave Lodge Using Our Epoxy Resin System, Materials and Plans

This is a step by step guide to building the U K Epoxy resins Dory Skiff "Morgan" The plans for this boat are supplied Free when you buy the resin kit to build this boat, you supply the plywood and timber and time, we supply the Resins, fillers, fibreglass tape and fabric, mixing and measuring equipment, brushes and rollers

 Dave getting ready to star building Morgan

Dave in his new workshop marking out and cutting templates ready for marking and cutting the hull timbers.
He has chosen to produce templates as he is going to build more than one hull, however if you decide to build "Morgan" then you can mark out the components directly onto the timber.

The image on the right shows a completed template of the stern seat bulkhead ready for marking out onto the plywood.
The two images below show the marking out and cutting of the plank stock from two standard 8' x 4" (2440 x 1220 mm ) plywood sheets scarfed together to produce a 15' 10" x 4' ( 4826 x 1220 mm) sheet, two of these long sheets are required to produce the planks all the rest of the components are cut from standard sheets.

Making templates
Cutting out the plywood planks  cutting ready lofted planks
Stitching the planks to form the hull

The image on the left shows the hull stitched together and the temporary bulkheads located in position to give the hull its correct shape.

The image on the right again show the stitched hull with the temporary bulkheads fitted and showing the cutouts over the plank seams to enable both the easy filleting and laying the fibreglass tape over the plank seams.

Hull with temporary bulkheads in place
applying the first coat of resin mix  applying fillets

The image above left shows the seams being primed with resin/hardener mix prior to being filled above right with high density filleting mix. It is a good idea to tape up the outside of the seams with parcel tape so that any squeeze through does not drip onto the floor, it also serves a second purpose in that filler pressed between the planks is retained and fills the outside of the seam at the same time.

 applying tape through temporary bulkheads  Wetting ou the fibreglass tape

The above image on the left shows the glass tape laid along all the filleted seams you can see how the cut outs in the temporary bulkheads allow the tape clear runs. The image on the above right shows the tape being wet out, again the cut outs assist in giving clear access to the seam. It is a good idea to cover the the edges of the bulkheads and areas in contact with the hull with candle wax to prevent any resin drips making your temporary bulkheads a permanent feature.

locating f'ard bulkhead  filleting the f'ard bulkhead

The image above shows the f'ard bulkhead located and ready for filleting above left.

 fitting mast socket F'ard bouyancy tank and mast socket
 fitting fordeck

The image above Left shows the mast bulkheads being located.
The image above right shows the mast bulkheads and the centre support rib fitted ready for filleting and taping.
The image on the left shows the for deck located prior to cutting out the mast socket.

It is a good idea to leave the final fitting of the for deck until all bow fittings have been installed towing eye's etc..

after deck supports fitting after deck

The image above left shows the after deck bulkhead located and the centre support rib being fitted.
The image above right shows the after deck in place again it is a good idea to leave final fixing until things such as rudder pintles are fitted.

 clamping centre board case locating centre board case in hull slot
Bonding centre board case to hull  

The three images above and to the left show the centreboard casing assembled and clamped into place for bonding. The inside faces of the casing have been sheathed with 200 gm glass fabric prior to assembly.

The image to the right shows the centre board shaped and ready for sheathing. It has been pre loaded with sheet lead in the centre lamination and has had a hardwood pivot point, in this case is made from Lignum Vitae and should never wear out

Centre board
Centre board thwart  Centre board thwart fitted
Centre board thwart bonded and filleted

The three images to the above and left show the cent re thwart being fitted.

mast socket mast socket drain

The image above and to the left shows a copper pipe set into the bottom of the mast box the image above and right shows the outlet into bilge.

Sutton Hoo sampson post  Sutton Hoo sampson post

The above images show Dave's artistic skill, he has decided to add a Sampson post for mooring and has added an additional bulkhead in two sections to support it the carving is Dave's handywork and is his interpretation of the helmet fond in the Sutton Hoo Anglo Saxon burial ship found in Woodbridge in Suffolk England.

rudder sections

The image to the left is the three sections of the lead weighted rudder ready to be bonded together and shaped.

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