Epoxyworks 51 Is Also Available As A

FREE BUILDING, RESTORATION & REPAIR with EPOXY Number 51 Fall 2020 In this issue EPOXYWORKS ® Editor/Designer Jenessa Hilger Managing Editor/Copy Editor Grace Ombry In This Issue Contact/Subscriptions Mari Verhalen Jon Staudacher’s Scientific Approach to Projects 1 Contributors Bill Bauer, Pat Dammer, Rachael Don Gutzmer shares some of the recent projects noted Geerts, Don Gutzmer, Jared Kramer, Mike Lenemen, designer and builder Jon Staudacher has been working Jeff McAffer, Terry Monville, Bruce Schinder on and his innovative solutions. Epoxyworks is published twice a year by Gougeon Brothers, Inc., Bay City, MI, USA. Quality Control: It’s what we do 4 At WEST SYSTEM we take quality control very seriously. Product Number 000-605 We want to be sure you get consistently excellent epoxy © 2020 by Gougeon Brothers, Inc. Reproduction in any form, every time you pick up a can off the shelf. Here are some in whole or in part, is expressly forbidden without the written of the tests we do to ensure that promise is a reality. consent of the publisher. Epoxyworks is a registered trademark of Gougeon Brothers, Inc. Understanding Impact and Abrasion Resistance 6 WEST SYSTEM, 105 Epoxy Resin, 205 Fast Hardener, 206 Slow Hardener, Skid plates take a beating from impacts and 410 Microlight, G/5, G/flex and Six10 are registered trademarks of abrasions on small boats. Here are some things you Gougeon Brothers, Inc. 207 Special Clear Hardener, 209 Extra Slow can do to give your boat the best resistance against Hardener, 422 Barrier Coat Additive and Episize are trademarks of this type of damage. Gougeon Brothers, Inc. Mammoth Tusk Restoration 8 Subscriptions, US and Canada Check out the beautiful way Bruce Schinder is Epoxyworks subscriptions are FREE to US and Canadian perserving mammoth tusks as pieces of art after they've been discovered in the melting permafrost. addresses. Subscriptions do not expire. To start or stop a subscription, change address or subscribe for a friend, Surviving FLICKA’s Capsize 10 complete and return the tear-out mailer or call 866- You've been waiting, and now here it is. The second 937-8797 toll free. You may also subscribe via e-mail and final installment of Jan Gougeon's survival of the to [email protected] (be sure to include capsize of FLICKA. your mailing address) or by filling out the subscription form at epoxyworks.com. Our mailing list is strictly Carbon Skinning 14 confidential and will not be sold. Looking for a way to update his racecar dash for better viewing by his 360-degree camera audience, and make his car the envy of the other racers, Jeff McAffer skinned Contribute to Epoxyworks his dash with carbon fiber. The results are stunning. If you have completed an interesting project, or developed a useful technique or a practical or unusual Making Knives with G/flex 18 use for epoxy, tell us and your fellow epoxy users about Maker of custom knives, Jared Kramer, explains why it. Send a photograph or two, or e-mail digital photos he chose WEST SYSTEM G/flex for a long lasting, high (about 300 dpi). Include a note describing the project quality product. and how we may contact you. By sending photographs you are granting permission to publish your photos Choosing the Right Wood for Your Boat Repair 19 in Epoxyworks and other Gougeon Brothers print and There's many options for replacing rotten plywood online publications or promotional presentations. in your boat. Here are some things to take into Mailing address Epoxyworks consideration as you're preparing for your next repair. P.O. Box 908 Gaff Repair 22 Bay City, MI 48707-0908 Tall ships are inspiring to watch skimming across the Email [email protected] water. Behind all that beauty is a lot of hard work to keep them functional. Bill Bauer walks us through the repairs done after a Coast Guard inspection of Appledore IV and V's gaffs. Epoxyworks Online Visit epoxyworks.com to browse back issues, look for Thickened Epoxy Application 24 specific topics, or share articles on social media. Here's a simple, cost effective, disposable way to apply a bead of thickened epoxy to your next project. THE ANIMAL has exceeded 100 mph Jon Staudacher’s in test runs. Approach to Projects By Don Gutzmer - GBI Technical Advisor My good friend and previous employer, Jon the center of the sponsons and the areas aft of the Staudacher, always surprises me with how he engine compartment. The boat weighs only 960 designs and builds his projects. Jon creates lbs. without the motor. everything from hydroplanes to airplanes using He used scrap wood for the trusses. Jon materials and methods that are logical and always minimizes waste and often finds ways to practical. He would say he treats most of the things incorporate it into the build. Cover Photo: THE he builds like a science project, experimenting To help increase the turning fin attachment’s ANIMAL along with new concepts in design and materials, and holding power, he cut a wooden block to create a side one of John's continually learning new things. I will explain channel for an aluminum rod that has machine other projects, an some of Jon’s unique approaches to a few of his threads in the end for a bolt. Jon used his lathe acrobatic airplane. recent projects. to machine the outside of the rod so notches ran Photo by Avram down the length of it. This helps increase the Golden The Animal - Wooden Hydroplane The first project is a wooden hydroplane boat that is powered with a Big Block Chevy 480 cubic inch motor. The boat was built using Hydrotek® marine plywood and clear spruce bonded with WEST SYSTEM® Epoxy. It’s a two-seat hydroplane so that non-racers can experience what it’s like The notched to travel 100+ mph on the water. What’s unique aluminum rod being about this design is the hull, which he built like an bedded in its wood aircraft wing. The height of the hull side is around housing. 34", ensuring the boat will float with substantial freeboard while increasing reserve buoyancy. mechanical holding power. He used WEST SYSTEM The boat’s longitudinal hull stringers are similar Epoxy thickened with 404 High-Density filler to to the ribs of an airplane wing. To minimize the attach the aluminum rod, then covered it with a overall hull weight, he designed the hull with wooden cap. This method ensures the outside of wooden trusses instead of solid bulkheads down the bar is encapsulated in epoxy and there are no Profile view of THE ANIMAL. Number 51, Fall 2020 1 on the ends. In order to use a Mercury propeller, he welded a splined Mercury driveshaft to the 4130 tubing at its largest diameter. On the other end of the steel shaft he welded a driveshaft coupler. The prop shaft tube eliminates the need for an expensive stainless steel prop shaft and reduces weight. Strange Magic - Trimaran Jon has been intrigued by sailing for many years and enjoys his Hobie Cat. He decided it would be fun to design and build a lightweight, competitive trimaran-using WEST SYSTEM Epoxy-to race Don and Jon watching air voids. The entire assembly can be epoxied in the THE ANIMAL on the hull at the desired location. Saginaw River. This is a major improvement over the usual method of drilling a hole into a wooden block after it is installed. That approach makes it difficult to coat the outside of the hardware with epoxy and can also leave air voids when the hardware is inserted. STRANGE MAGIC headed out to race on the Saginaw Bay. The aluminum/wood assembly epoxied into with the local sailing association. the desired location in The first step was building fiberglass ama the hull. hulls from a male plug. The ama bottoms are semicircular (170 degrees) and maintain a semi- The design for the propeller strut and shaft circular cross-section from bow to stern. The on the hull is also unique. The strut consists of plywood sides have a shallow bevel where the a hollow aluminum tube that is bonded on with fiberglass ama attaches to the bottom with G/flex® thickened WEST SYSTEM Epoxy. He applied 655 Thickened Epoxy Adhesive. The semicircular carbon fiber fabric and epoxy over the tube to tab hull bottom gains rigidity because of its geometry. it onto the hull. The frames inside of the amas are wooden trusses A view of the hull Jon’s design incorporated a steel propeller interior as it's being shaft made from 4130 Chromoly steel tube. The flipped over. aluminum strut is oil-filled with bronze bushings The hull bottom and the trussing for the ama ready to be assembled. Shown above is the semicircular, fiberglass hull bottom which will be flipped over and epoxied to the plywood trussing section of the ama. 2 EPOXYWORKS He designed the plane with a Chromoly tube truss fuselage, TIG welded to help carry the loads between the engine, wing, landing gear, and tail. The tube fuselage structure also provides safety for the pilot, helps transfer loads effectively, and is a great option for attachment points. The tail surfaces are integral with the fuselage/tail cone which eliminates the need for hardware and fairings. Jon built the wing with fiberglass/aluminum honeycomb ribs bonded onto its plywood skin. He has found that WEST SYSTEM Epoxy bonds the open cells of the honeycomb to the plywood very The final painted trimaran. well. On his previous aerobatic wing designs he has used pultruded carbon bars bonded to the wood made from scrap wood, with gussets.

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