Please select your home edition
Edition
SW newsletters (top)

West System epoxy used in building an 18th century Gajeta - Part 8

by Jake Kavanagh 27 Aug 2019 04:00 PDT
The new boat performed well at the annual Gajeta regatta © Event Media / www.regate.com.hr

In our latest instalment of the building of a replica of an 18th century Croatian Gajeta, 'Lipa Moja' becomes the sum of her parts. Many hours of craftsmanship - combined with the precision of CNC cutting and the adhesive power of WEST SYSTEM® epoxy - have resulted in a beautiful vessel that is ready to race.

Perhaps spurred on by the deadline for the local regatta, the 9m replica fishing boat Lipa Moja quickly comes together. This is largely due to her team working on separate components, all of which reach completion at roughly the same time.

Naval architect Srdan Dokovic's idea to recreate a classic boat using traditional craftsmanship merged with modern tech has paid off. The butterfly is emerging from her cocoon.

The shapes for the rowlocks, blocks and other functional pieces have been cut from solid mahogany - photo © Wessex Resins & Adhesives

The shapes for the rowlocks, blocks and other functional pieces have been cut from solid mahogany and coated with WEST SYSTEM 105 Epoxy Resin mixed with 207 Special Coating Hardener. The 207 hardener ensures a rich, deep gloss to the mixed epoxy coating and is usually built up in three layers wet-on-wet. When reinforced with several layers of UV resistant polyurethane varnish, the result is a transparent coating able to withstand the hot Croatian summer.

Sculls are made to the traditional pattern from solid lengths of pine - photo © Wessex Resins & Adhesives

Although assisted by a small diesel, the Gajeta is true to its roots in having a set of sculls on board. These are made to the traditional pattern from solid lengths of pine. Again, they are sealed with WEST SYSTEM epoxy before being over-coated with UV stable varnish.

The hull is now painted with a two-pack polyurethane paint from International's Perfection range - photo © Wessex Resins & Adhesives

The hull is now painted with a two-pack polyurethane paint from International's Perfection range. The beauty of two-pack is that it is incredibly tough and there is no wastage as the pigment is mixed in an exact ratio to the hardener. A coat of two-pack can last for many years if properly applied, which offsets the higher cost of the raw material.

After a coat of primer and two coats of undercoat, the hull is looking great - photo © Wessex Resins & Adhesives

After a coat of primer and two coats of undercoat, the hull is looking great. Two-pack paint cures (as opposed to 'dries') very quickly, which helps to speed up the painting process. The undercoat will protect the hull whilst the final work is done.

Next to go on is the toe rail, again made from mahogany and also coated with epoxy - photo © Wessex Resins & Adhesives

Next to go on is the toe rail, again made from mahogany and also coated with WEST SYSTEM 105 Epoxy Resin mixed with 207 Special Coating hardener to give that rich deep gloss. Note the drain holes.

Next to go on is the toe rail, again made from mahogany and also coated with epoxy - photo © Wessex Resins & Adhesives

Next to go on is the toe rail, again made from mahogany and also coated with WEST SYSTEM 105 Epoxy Resin mixed with 207 Special Coating hardener to give that rich deep gloss. Note the drain holes.

The aft deck is made up of 8mm teak planks set onto a bed of WEST SYSTEM G-Flex epoxy - photo © Wessex Resins & Adhesives

The aft deck is made up of 8mm teak planks set onto a bed of WEST SYSTEM G/Flex epoxy. This is a very tough, powerful thickened epoxy adhesive that has enough elasticity to allow the deck to move and so prevent any splitting. The seams are filled with a PU adhesive sealant. Large metal weights keep the whole thing flat during the curing process. The use of adhesive removes the need to screw the planks down, which eliminates potential leaks.

Note the proliferation of clamps. There never seem to be enough on a boat building project - photo © Wessex Resins & Adhesives

Everything starts to fall into place. The team omitted to photograph the engine fitting or the erection of the mast but we can see those from the finished item. Note the proliferation of clamps. There never seem to be enough on a boat building project.

With the mast in and the detailing complete, all that remains is for the boat to be named - photo © Wessex Resins & Adhesives

With the mast in and the detailing complete, all that remains is for the boat to be named. With so much work to get the hull smooth, no-one is going to risk denting it with a champagne bottle, so it is poured over the hull instead. That PU topcoat will shrug it off.

The new boat performed well at the annual Gajeta regatta - photo © Event Media / www.regate.com.hr

Underway and in her element. The boat performed well at the annual Gajeta regatta and turned appreciative heads wherever she went. Her epoxy sheathed and bonded hull will protect her for far longer than a traditional timber vessel, so this boat will be sailing for decades to come with relatively little maintenance required.

See more stories and tips at www.epoxycraft.com/projects/marine and epoxycraft.com/top-tips-best-ways-to-use-epoxy

Related Articles

Building a wooden dinghy with epoxy resin part 2
Strip planking the hull, and making an amazing wooden mast "You don't build your own boat to save money," Steve explains. "You do it for the sheer satisfaction of the craftsmanship involved. For what I paid in raw materials I could have bought several second-hand boats, but where is the fun in that?" Posted on 18 Mar
Epoxy Resin basics
Cure stages, controlling cure time, dispensing, fillers, recoating and more Tips for working with epoxy include: What is the difference between working time, pot life and cure time? Each hardener has an ideal temperature range. Primarily cotton flock, 403 is great for quickly thickening the epoxy. Posted on 11 Mar
The stuff AC75s are made of
INEOS TEAM UK's manufacturing team uses Super Toughened Epoxy In the high speed, high stress world of the America's Cup, keeping the beast in one piece is clearly a big challenge. Structural attachments that require an adhesive bond need a strong yet toughened epoxy adhesive to transmit loads between components. Posted on 9 Mar
Wessex Resins offers free repair demonstrations
'How to use epoxy' demos at the RYA Dinghy Show 2020 Wessex Resins and Adhesives is offering free repair demonstrations on its stand C2 (Hall Three) at the RYA Dinghy Show, Alexandra Palace, 29th February to 1st March. Posted on 19 Feb
Cheetah Marine story from 1989
A prototype catamaran was built using epoxy resin glue Cheetah Marine's prototype catamaran was built in 1989 on the Isle of Wight. Founder, Sean Strevens, built her with thin marine ply and WEST SYSTEM® epoxy, the original and best marine grade epoxy. Posted on 4 Jan
Building a wooden dinghy with epoxy resin part 1
Steve Goodchild talks us through the Stornoway 16 build, starting with the jig In part one of this series of how to build a wooden dinghy Steve Goodchild takes us through choosing a design, and making a jig for his Stornoway 16. Posted on 30 Dec 2019
Epoxy-related presents for sailors
There's a whole range of different packs you could give If you're looking for presents for sailors, take inspiration from George Isted's recent win. He's giving some of this mega-bundle of epoxy goodies as gifts; sharing the epoxy magic as Christmas presents for sailors in his life. Posted on 12 Dec 2019
Building an 18th century Gajeta part 9
Amazing beauty of an old wooden design built with modern epoxy resin As you'll know, we've run a series on the build of a wooden Gajeta with epoxy resin at the Betina Shipyard in Croatia. In this final instalment we look back at where she started and what she became. From 3D design to the final item. Posted on 15 Nov 2019
Moulding an oil drip tray with epoxy resin
Techniques used here are good practice for bigger projects The beauty of epoxy, says Jake Kavanagh, is that it makes a tough, non-shrinking connection between various angles of wood, ideal when you want to make a plug for a custom mould. Which is why he wrote this article on how to make a oil drip tray. Posted on 8 Nov 2019
Flying High
J-TEC Composites interviewed about use of Wessex Resins and Adhesives James Newman, J-TEC Composites, says his favourite part of making products is the final outcome, when he sees the face of the customer realising the part 'does what they want it to do'. Posted on 31 Oct 2019
MBW newsletters (top)