Wood/Epoxy Composite Construction

Epoxy composite construction has revolutionized boat building over the last 25 years. Boat builders can build stronger, lighter and more durable boats than ever before. 

Epoxy composite construction consists of bonding all materials and parts of the boat together, resulting in a structure superior to the components by themselves. The key ingredient in composite construction is epoxy, a versatile thermo set plastic. The moisture resistant properties of epoxy adds to the advantages of the wood: strength, stiffness, light weight, resistance to fatigue, availability, cost, and beauty. Because all components are protected by an epoxy moisture barrier and the moisture content is stabilized, problems associated with wooden boats: rot, joint cracks, and swelling or shrinking of structural members are eliminated. 

As Epoxy Composite builders, we are able to offer boats in a wide range of designs, materials and construction methods.

Methods of Epoxy Composite Construction

Cold Molding
This technique creates a laminated wooden hull. It involves the bonding together of wood veneers or thin planks with epoxy resin to make a strong lightweight watertight hull. The hulls have excellent strength for weight characteristics and longevity.

Strip Planking
This is a related technique to cold molding. It uses narrow strips of wood to form the hull which are glued with epoxy and edge nailed. The hull is sheathed with fiberglass cloth and epoxy resin. The techniques of cold molding and strip planking are often combined to build larger vessels.

Stitch and Glue
This technique uses sheet marine plywood, wire, fiberglass tape, epoxy glue and epoxy fillers to create a strong monoque hull.

Plywood Construction
Marine Plywood planking on sawn frames, sheathed with fiberglass cloth and epoxy resin.

Core-Cell Composite Construction

Core-CellŪ is a new generation linear polymer foam for use as a sandwich core primarily in high quality boats. Its main properties are damage tolerance/high impact strength and good thermal resistance so that Core-Cell can be used in hulls, decks and superstructures. 

Core-Cell linear structural foam was developed specifically to meet the needs of the performance oriented marine market. Core-Cell creates structures that are both stiff AND tough, a combination of features other core materials cannot offer. In addition, a suitable core must provide sound and thermal insulation, be impervious to water & be rot-proof. In short, a good core must offer a variety of features to qualify as a high performance core material.