Excess Poxy

Where to put that excess poxy?

The stuff is too expensive to just throw away. 

I built a little dam in the bow of my kayaks and kept pouring/placing anyexcess in there to reinforce the fragile bow and to accommodate the bow loop.

Poxy with wood chips placed in kayak bow

Using excess poxy, I built up a glob in the stem of the sharpie, scull and Boat BW to accommodate the bow loop.

Poxy with wood chips placed in stem of sharpie

Completed glob in stem of sharpie. The bulge is where the bow
loop passes through

Wood chip-thickened poxy in bow of scull.
Looks like I recently poured a bit of excess neat poxy
on top

Start of the glob in the stem of the BW

The glob in the stem of the BW is growing

Read more about the infamous glob in the Boat BW at Glob Blog

Parfait Anyone?

While building the BW, after the glob was complete I started dumping the excess poxy in a wax cup. When the cup was full, I peeled the wax cup away. 

That cup is the only poxy thrown away during the building of the BW which consumed 32 gallons of poxy. Always having a next step ready for the excess poxy is the trick to avoiding waste.

Crackers Anyone?

Then I coated a couple of Saltine crackers with neat poxy and topped them with thickened poxy.

Poxy thickened with powdered silica and wood flour

Poxy thickened with powdered silica, wood flour and wood chips

For a while I refused to discard the used disposable foam and chip brushes and stacked them artistically (well, as artistically as I am capable). The residual poxy in the foam/bristles glued them all together into a glorious sculpture.

Disposable brush sculpture

If the poxy manufacturers would meet my demand for edible poxy, use of the excess poxy would not be an issue.

Bon Appetit

Photo Bucket

Butt-Block for joining plywood while avoiding scarphing

Butt-Block for joining plywood while avoiding scarphing

Hydrotek BS-1088 Meranti 9-ply 1/2-inch (12mm) Plywood.

Plans Now Available

I have created a set of plans for building the BW. These are very detailed plans complete with pages of thorough step-by-step instructions with numerous photographs, and 21 detailed, scaled, computer-drafted drawings with all the necessary dimensions.

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Boat BW Specifications

Construction:	Plywood/fiberglass/epoxy stitch-and-glue
Hull Type:	Planing, semi-V, 8° deadrise aft, 12° deadrise mid-ship, chine flats and lifting strakes
Length Overall:	23 feet
Beam at Sheer:	7’-9”
Beam at Chine:	5’-9”
Draft:	6 inches with outboard motors up
Hull Thickness:	Bottom: ½ inches, deck: ½ inches, sides: 3/8 inches
Side flare:	20°
Deck:	Continuous from chine-to-chine. Not self-bailing
Weight (empty, hull only):	2,000 pounds
Power:	Outboard motor or motors totaling 100Hp
Maximum weight hanging on transom:	400 pounds
Transom angle:	15°
Speed:	31 knots with twin 50Hp OBs at WOT
Fuel Consumption:	1.8 gallons per hour per OB, at 24 knots with twin 50Hp OBs

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FAQs

How much did it cost to build the BW?

In 2016, it cost me $11,200 USD for the materials to build the BW hull with an anchor well, a forward locker, a fuel locker, a steering system and a pilothouse console with laminated safety glass windows. I used Hydrotek BS-1088 meranti plywood which is more expensive than run-of-the-mill marine plywood. 

Here is my 2016 cost breakdown for the hull only, not including a boat trailer, outboard motors, fuel system and USCG-required safety gear:

In addition to the costs described above, I paid $4,500 USD for a new galvanized boat trailer, for a total out-of-pocket investment of $15,700 USD. 

In addition to the $15,700 USD, there will be costs for outboard motors, associated fuel systems and USCG-required safety gear.  

How long will it take to build a BW?

For the hull with an anchor well, a forward locker, a fuel locker, slopwell and a modest pilothouse console, I spent 600 hours building it. Being that the BW was the tenth boat that I have built, it will probably take most people a bit longer.

The hours spent working on the boat are not the only consideration. The calendar time also matters. Due to the curing time of epoxy, it is difficult to work more than a few hours a day. After a few hours you will have something glued with epoxy that cannot be disturbed until the epoxy cures. This often ends the day’s work session. That is why even though it took me only 600 hours, it took 15 months to build the BW.

It is possible to reduce the calendar time by having several things being fabricated at the same time so that when one item is waiting for the epoxy to cure, you can be working on another item. However, this takes planning and a large shop.

How big of a shop will I need?

I built my BW in a shop that was 12 feet wide x 25 feet deep. But the width available for the boat was only 10 feet due to a 2-foot workbench that runs the length of my shop.

It was tight. I had to build all the big items and hang them from the ceiling before starting to assemble the hull. Once the hull started being assembled, the hull took up most of the shop space and I had little room for anything else.

I put the hull on a wheel dolly so I could push it to one side of the shop for working on the starboard side of the boat. Then I would push the hull to the other side of the shop to work on the port side.

How experienced should the builder be?

The BW is a big home-build project. It is larger but not much more complex than the kayaks, dories, drift boats and little runabouts that are common first-time-builder stitch-and-glue boats. Due to its size, the BW will take time, space, money and patience to complete.

Some, but not much, woodworking experience is necessary. There is no complex joinery and only a few compound angles. A little ability to read plan drawings is required. 

However, stitch-and-glue boats are amazingly forgiving since epoxy is really strong and you can use thickened epoxy to fill in and fair over carpentry imperfections then hide the faired imperfections with paint. This is why shipwrights hate stitch-and-glue boats and call them Bondo Boats. 

The instructions are well-organized with table of contents,  glossary, detailed bill-of-materials etc.

The instructions contain tutorials for each process in the stitch-and-glue and WEST system of plywood/epoxy boat building.

Every little step is outlined as needed for the beginning boat builder but still suitable for the experienced builder. Photos accompany every major stage of the build.

Included are 21 detailed, scaled, computer-drafted drawings with all the necessary dimensions.

Also included are instructions and drawings for the optional pilothouse console.

$35USD

If interested, please email me through View my complete profile in the upper right corner at the top of this page.

Cookie Method

So you have decided to treat yourself to a boat. You are the do-it-yourself type and you are trying to decide between building a boat or buying a boat. You have the time, patience and space to build a boat and you are wondering whether to build from scratch or build from a kit. Yet those are not the only options.

Here are some of the common options:

• Wing it without plans and build from scratch.
• Follow a set of plans and build from scratch.
• Build from a pre-cut kit.
• Buy a ready-to-go boat.

None of the options is any better than the other. All have merit and which way to go is simply a matter of personal preference. Which option is best for you?

Before you decide, you might want to factor in consideration of the future. When launching or retrieving your boat, someone may ask, “Did you build that boat?” You may feel different levels of satisfaction when answering “Yes” compared to when answering “No.” If you answer “Yes” be prepared for the next series of questions, “Did you build from a kit?” “Did you use a set of plans?” What answers would grant you your desired satisfaction?

Your decision will require some introspect to determine your personal preferences. I like to use the cookie method to provide introspect into myself. Here is the cookie method.

I have decided to treat myself to cookies. I have the time, patience and space to bake cookies and I am wondering whether to bake from scratch or buy some cookies? Those are not the only options.

Here are some of the common options:

• Wing it without a recipe and bake from scratch.
• Follow a cookie recipe and bake from scratch.
• Bake them from pre-mixed batter.
• Buy ready-to-eat cookies.

None of the options is any better than the other. All have merit and which way to go is simply a matter of personal preference.

But before I decide, I factor in consideration of the future. When sharing the cookies, someone may ask, “Did you bake these cookies?” I feel far different levels of satisfaction when answering “Yes” compared to when answering “No.” If I answer “Yes” I am prepared for the next series of questions, “Did you use pre-mixed batter?” “Did you follow a recipe?” The answers that grant me my desired satisfaction are factored into my decision.

When I bake cookies I always bake from scratch. I have never baked from pre-mixed batter. I have occasionally bought ready-to-eat cookies. When I bake from scratch I usually start with a recipe but I always wing it a bit by varying slightly from the recipe. I love it when someone asks, “Did you make these cookies?”

When I build a boat I always build from scratch. I have never built from pre-cut kit. I have occasionally bought ready-to-go boats. When I build from scratch I usually start with plans but always wing it a bit by varying slightly from the plans.  I love it when someone asks, “Did you build this boat?”

As you try to decide between building or buying a boat and you consider the different options for building, maybe the cookie method will also help you understand your preferences.


Other blogs by Mo 'Poxy:

Renovating the boat Lady C

Building a CLC Chesapeake kayak

The difference between course, heading and bearing

Building the boat Lady C

Building a remote cabin

Building a sea scull

Building the boat Nemah