fairing the glass/epoxy sheathing

 hull coated with epoxy and phenolic microballoons,

and wet sanded with 80 grit on the agony plank

 bilge area recoated with neat epoxy after sanding

Filling the cloth with epoxy

 1st epoxy coat applied with 10" window sqeegee

coats 2 and 3 applied with 3mm foam roller to fill the cloth weave

Glassing the main hull

 6 oz glass cloth held in place by tape and staples thru veneer scraps

 ready for epoxy saturation

2" overlap at keel and stem

gluing the crossbeam web scarfs

 detergent jugs & old car batteries used as weights over scarf to ensure a good joint,

excess epoxy squeezes out,

you can't see it easily, but the plywood is set out over the top of the cardboard template,

which is taped to the floor,

all this to ensure proper alignment at the scarf

only 16 foot flat spot I could find for assembly

was dining room / living room floor

(wax paper on floor under glue joint)

cross beam scarfing

 12:1 scarf in 1/2" beam web plywood

 fits real nice,

pencil lines are 1" from each planned scarf edge and are used to control the overlap amount,

they should be 8" apart after the joint is completed,

you can't reliably use the wood edges since

 they may be slightly ground away by the planing process

 special attachment for electric planer to make 12:1 scarfs

 extensions of attachment keep planer at the correct tilted depth across the workpiece,

the work table has 12:1 ramps on each side,

the planer rests on them as you cut across between them

 some reinforcing to prevent any flexing in the attachment

planer attachment has stops to prevent the planer blade from carving into the ramps

cross beam templates

 carefully drawn cardboard (bristol board) templates drawn 

from autocad dimensions to get the curved shapes accurate

 the cardboard templates can be traced around, 

making it easy to draw the same accurate shapes 16 times on plywood

beams are almost 16 feet long, 

plywood is 8 feet long, 

so two 8 foot templates attached end to end to make a beam,

Lock specifies a 12:1 scarf, so the 1/2" plywood will need a 6" overlap,

this is allowed for in the templates

 templates placed on plywood and adjusted to minimize plywood waste

Starting the cross beams

 top quality clear western red cedar 2x6 for the beam laminations

absolutely clear and straight, from Sawmill Sales Direct,

some scarfing required for length

2nd filler application

 used microlight for 2nd layer of filler

nice feather edges and sands very easily

1st filler application is sanded smooth

 epoxy / microballon filler sanded smooth with 50 grit belt sander

ready for another application of filler to fill minor flaws

1st application of filler

 epoxy and phenolic microballon filler 

all edge joints between veneers

and staple marks are filled

general fairing

- chalk lines to find hi and lo spots

- 32" agony plank for fairing

general fairing / shaping done

- ready for filler

oak armor around transom

 1/8" oak veneers laminated around transom edge,

for dingy ding protection

sanded off flush