Nauticat 52 Refit

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Glass rack. Built this setup for $100 in materials.

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1200- 12 oz. 0/90 S glass.

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1 1/2 oz. matt.

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1700- 17 oz. +/- 45. DB with no stitch matt.

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The first piece of foam core is patterned and cut. This is 10 lb. rigid urethane. We usually use five or six pound.

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Super fast and easy.

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Bosch jig saw with zero angle stroke and carbide abrasive blade turned way down cuts very nice. Laminate trimmer with radius bit for making perfect radii.

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Drops right into place with no trimming at all. Perfect fit every time.

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Like a glove.

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Dry fit with battens. Normally I'd bag something like this, but it's really not necessary here. Ten lb. is stiff enough for the batten method to work very well, and it's so much faster.

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Core Bond. This stuff is the only way to go for core bonding. Sticks like crazy, long pot life, low exotherm, very light weight, flexes without cracking, etc. etc. Accept no substitutes. Catalyzes with BPO only.

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Underside of core is coated with thinned down poly resin, several times, till it won't absorb any more.

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Catalyzed core bond troweled on with a notched spreader.

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Ready for core.

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I like WEST System notched spreaders. Nothing sticks to them, so you don't even bother to clean em. Just come in the next day and flex it a few times and all the stuff just pops off and leaves you a shiny new spreader!