Cold molded hulls have been built since the technique was used for World War II planes—often using casein or urea-based glues. Today, one would use epoxy almost exclusively, benefiting from its superior bonding, gap-filling, strength and water resistance.
The temporary framework (or jig) will commonly allow for a permanent gunwale to be fitted as well as a keelson, as the diagonal veneers will be permanently attached to these.
Wood for the veneer strips is very critical. It must be cut flat with even thickness, be well seasoned and resistant to cracking. Western red cedar and mahogany are two good choices. Some builders even use thin, high quality plywood.
The pre-cut veneers (2–6 mm thick depending on boat size, bilge radius and stringer spacing) will typically be laid up about 35-45 degrees from the vertical and stapled to the stringers where they cross and also near both edges.
Veneer width will depend on the curvature of the hull, with more curvature requiring narrower strips. Knowing what radius various woods can bend will help decide the strip size and thickness for a particular shape.
This table is from a fine book entitled 'The Gougeon Brothers on Boat Construction' - with their kind permission.
Veneers
Thickness (in inches)
Radius (in inches)
Dark red meranti Douglas fir Sitka spruce Red cedar
If the staples are arranged in a row and a strip of tough strapping material laid under them, they will be much easier to remove without damaging the wood.
(This sketch also comes from the excellent book 'The Gougeon Brothers on Boat Construction' and shown here with their kind permission)
After the 2nd layer, modern builders are now often enclosing the whole surface with plastic and vacuum-bagging the bond to improve pressure between the surfaces while curing. But this requires that the working surface of the mold be made air-tight and that is impossible with an open frame+stringer arrangement. One interesting method (see URL below for Nexus Marine) is to seal the first layer airtight and then vacuum bag to that. Either way, if it can be done, vacuum-bagging is surprisingly effective and not that difficult either as long as certain precautions are taken (see separate article on this).
Some larger designs call for a 3rd veneer layer—perhaps even laid up fore and aft for appearance. In such a case, this could well be the hardest layer to fit, especially if the hull has a sharp radius in its section. Narrower strips will help in this case but that means more joints to fit. (I'd personally suggest to avoid a lengthwise veneer and plan on painting the exterior.) Once cured, the exterior is typically sanded and at least partly faired before removal. Cold-molding is good when you have a capable partner to work with as you can each work on strips, starting amidships.
Click here for clear photos of the process: www.sixrivermarine.com/Cold%20molding%20QA.htm www.nexusmarine.com/odysy_const.html (with vacuum bagging) www.bruceroberts.com.au/gallery/index.htm (see Roberts 24 and Roberts 25 wood)
Advantages are: If well executed, this system produces a very tough, long-lasting hull that is stiff and resistant to damage and rot. It requires only the minimum of internal stiffening. Still a useful option where labor costs are low or just not counted.
Disadvantages: The system is pretty labor intensive and solid veneers of moisture-resistant wood are also becoming expensive and difficult to obtain in some parts of the world. The system also requires a good, solid mould prior to construction, which has no further use after the hull is lifted off. The surface, both inside and outside, also requires a considerable amount of sanding and the outside will need additional fairing to get a professional finish. As this is more work than other competing systems, this system is now used less and less, except where labor costs are low or discounted. The Constant Camber system was first developed to try and overcome this high labor issue—see separate article.
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Yachting World
Digital Edition
LA 28: The modern trailable boat that’s cold-molded from mahogany
October 8, 2019
The LA 28 is a beautiful, cold-moulded wooden trailer-sailer that was designed to be unique, and has now sold nine boats across Europe. Sam Fortescue steps on board
Appropriately, it’s a long train ride through thick, thick forest before I reach the LA Yachts yard on the banks of Lake Müritz in central Germany. This seems apposite because the boat I’ve come to see is an exquisite example of how wood is just as relevant as ever when it comes to boatbuilding.
In truth, the LA 28 has little in common with the endless rows of fir that fringe the lake; she is cold-moulded from nobler stuff. But it is striking that this young shipyard chose to build in wood. I ask yard owner Lothar Fichtner why.
“It’s lighter than GRP and cheaper than carbon,” he says without blinking. So much for the romance of traditional construction, then. In fact, there’s little about this vessel the boatbuilders of 100 years ago would recognise.
Around 60kg of Sicomin epoxy is used in the lay-up. Photo: Soenke Hucho
For one, cold moulding is a technique that relies heavily on epoxy resin to stick each layer of wood to the last and sheath the whole structure to keep the water out. Then there can be as much or as little carbon in the rig and the finish as you want, while propulsion comes courtesy of a Torqeedo electric motor.
Despite her elegant tumblehome and the plunging curve of her coachroof, this is a thoroughly modern boat. “The best of modern and traditional,” Fichtner says.
The story of the LA 28 begins with the desire of a wealthy man to have a beautiful sailing toy. Lothar Fichtner was that man and, having sold his engineering business, he wanted to enjoy more of life from his second home on Mallorca.
Article continues below…
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He approached a boatbuilder in the Muritz region called Andreas Zehle who specialised in the building of the German 20er Jollenkreuzer racing dinghy class, also cold moulded. Then he drafted in designer Martin Menzner from Berckemeyer Yacht Design in Laboe on the Kieler Fjord.
This small design house has worked on everything from dinghies to high-latitude yachts, using a range of construction materials and techniques. Crucially, Berckemeyer is strong in cold-moulded yacht design, or ‘speed strip’ as they call it.
The brief was for a trailerable 8-9m boat, that was “simple to rig, as single-handed as possible and with excellent sailing characteristics,” Fichtner explains. “I am bothered by the current development in boatbuilding. Almost all boats look the same. I wanted something exclusive that is modern in design and traditionally built.”
It takes more than 15 coats of varnish to achieve this degree of shine on the finish. Photo: Soenke Hucho
Menzner is a successful J/80 sailor himself, and the two men quickly saw eye-to-eye. The whole design process took just three months. Fichtner had no clear idea of it at the time, but he wasn’t just buying a boat, he was establishing a yard.
“I founded the shipyard because two boatbuilders were unemployed and I wanted to have a boat for my area in Germany and Mallorca,” he recalls. But one thing led to another, and Fichtner is a naturally ambitious man.
“We had a lot of success at trade fairs and continuous orders. Then I found my way into Germany’s Yacht magazine.” They have now sold nine boats since 2015, when the first garnered rave reviews at Interboat in Friedrichshafen.
Working with wood
Cold moulding requires a rough plug to be made, but no female tooling is needed, making it much cheaper to set-up than in the case of GRP or carbon. The plug around which the hull is formed is simply made from strips of softwood fastened around CNC-milled frames. It’s quick, cheap and relatively easy. The natural flexibility of the 2.5mm strips of wood used in cold moulding the hull iron out any imperfections in the mould.
The first stage of the process is to place a layer of plastic sheeting over the mould. Then the strips are bent into shape and clamped in place to hold their form. Each layer is bagged and vacuum infused with Sicomin epoxy resin, which soaks into the very top layer of the wood and helps to bond each strip edge-to-edge.
Each layer is laid in a different direction to the previous: longitudinal strips of okoume first, then lateral, then diagonal. For the outer layers, Lothar prefers African mahogany (khaya), giving a warm, reddish finish to the hull, which is many times stronger than the equivalent in glassfibre, and lighter too.
The deep curve of the tumblehome is all part of the hull shape, so it isn’t possible to mould the whole hull at the same time. Instead, there are two symmetrical plugs, one for the port side, one for starboard.
When the two halves are finished, they are simply epoxied together in the middle with a sort of low keelson covering the whole length of the joint for extra strength.
Cold moulding leads to a beautiful interior finish. Photo: Soenke Hucho
At this stage, the hull is still just a hollow form, albeit a beautiful one. Extra strength must be added next, which is achieved by ‘backfilling’ frames, ringframes and stringers – all glued into place after the event. These support the stresses of the mast, the shrouds and the keel, and provide structure for the transom, keelbox and so on.
The finish is a matter of personal taste – every owner makes their own decisions on this. Some have opted for carbon detailing; a layer of carbon epoxied around the aluminium mast post, for instance, a carbon keelbox and carbon fibre pads where the line for the retractable bowsprit passes through the companionway bulkhead into the cockpit. The mast and boom are both in carbon, with sails recommended in X-Drive carbon from UK Sailmakers.
Others have requested a white painted interior (a lot more work, observes Fichtner), or different woods used in the construction process to give a slightly different finish. The point is that every boat is unique and can be formed and specified to fit its new owner’s wishes: engine or no engine; spade rudder or transom-mounted kick-up rudder.
LA Yachts uses a very light wooden core for the tiller, then laminates it with carbon fibre. Photo: Soenke Hucho
Below the waterline the usual keel is a 600kg lead bulb, but again you can choose from a number of options. With the fixed keel there is the option of a 1.7m, 1.8m or 1.9m draught – depending on where you sail and how aggressively rigged she is.
But the hydraulic lift is proving a popular option, which reduces draught by 0.9m in the raised position. It’s a handy option for shallow waters, and makes it more feasible to land wherever the fancy takes you – perhaps with a family and a picnic basket.
True to the boat’s thoroughly modern character, Fichtner worked closely with Torqeedo in designing the LA 28 to use one of the company’s 2.5kW electric drives.
This is permanently mounted on a pod under the cockpit, but the throttle lives out of sight on a fold-down panel that pops out of one of the cave lockers. It’s a neat solution to the fact that the Torqeedo control is chunky and modern, and rather at odds with the otherworldly lines of the LA 28.
Controlled growth
The boat is resolutely designed to be simple to handle. “They sail easily and they’re very light. I can come into port by myself, and handle her myself,” Fichtner says. “With a bigger boat you always need a team – you are never alone.”
That said, there is a bigger boat on the horizon. Taking its cues from the look and handling of the LA 28, a larger 35-footer has been designed and will shortly enter the build phase. At 10.8m long, she can still be trailered, thanks to an all-up towing weight of just less than 3.5 tonnes.
“I want to invest in quality,” says Fichtner determinedly. “My dream would be to build just three boats per year.” There seems to be a preponderance of billionaires among the ownership ranks of LA Yachts, so perhaps three a year is more ambitious than it sounds.
Your life is complicated. Your boating shouldn’t be.
Presenting the LM46, a high-performance, bespoke sailing yacht that will reconnect you to what matters. With a low-maintenance, cold-molded hull that offers the unmatched, comfortable motion and ambiance of a wooden boat with the 10-knot-plus speeds of a modern performance yacht, you and your family will form a bond with the LM46 that will last generations.
Partnering with longtime friend and acclaimed Kiwi yacht designer Kevin Dibley, we’ve designed the LM46 to return sailing to being about sharing time with friends and family, enjoying a drink in the cockpit after a great day underway, and appreciating the beauty of our surroundings. Comfort doesn’t come from jamming every shoreside amenity into your boat, it comes from the reassuring motion of a Douglas Fir/Western Red Cedar hull sliding quietly through the water, the knowledge that you have everything you need aboard (and nothing more), and the satisfaction of owning a yacht that makes a statement about its owner. Our goal for the LM46 is simple: To have you sailing within 5 minutes of stepping aboard, and to be able to step off within 5 minutes of picking up your mooring.
Make no mistake: This is no docile, classic wooden boat. We have designed an extremely fast yacht, one that can put itself at the top of the fleet in almost any race, coastal or offshore. A top New Zealand design coupled with cutting-edge Lyman-Morse Maine craftsmanship makes for a winning combination.
Click here to see photos of the construction of LM46 hull No. 1 at Lyman-Morse in Thomaston, Maine. LM46 hull No. 2 is also under construction at Lyman-Morse.
Contact us today and rediscover what it means to be on a boat with soul.
Specifications
draft 6'0" (shoal) or 7'7" (standard) or 10' (performance)
displacement 24,750 lbs (6' draft) or 24,250 lbs (7'7" draft)
fuel capacity 81 gallons
water capacity 156 gallons
type Sail - 1,183 sq. ft.
designed by Kevin Dibley
builder Lyman-Morse Boatbuilding Co.
construction Wood composite
hull material Douglas Fir/Western Red Cedar
configuration Sloop
location Thomaston, Maine
boat engine Yanmar 4JH80 or 4JH110
horsepower 80 hp or 110 hp
Performance
The LM46 was built with the recognition that two boats sailing in the same direction, at the same time, constitutes a race. A powerful cruising rig that includes swept-back spreaders and 1,183 square feet of sail, including a squaretop main, gives the LM46 an impressive turn of speed; rolling out the optional asymmetrical spinnaker steps thing up a notch and lets the yacht hit speeds of 10 knots or more. When conditions are right, this yacht can click off 240 miles per day, while the wooden hull, 43’ waterline length, and comfortable displacement-length ratio of 133 allows for one-handed steering or easy steering by autopilot, no matter the weather.
Like everything else aboard the LM46, sail-handling is kept simple, efficient, and user-friendly: roller furling for the jib, a detachable staysail, and a mainsail furling system that is fast, easy, and effective. Following the French lead, we’re keeping weight out of the bow of the LM46 by using almost all anchor rode instead of chain. Quiet, easy — just like the LM46 itself.
And while the LM46 revels under sail, it can also deliver its crew just as swiftly under power, with an 80- or optional 110-horsepower Yanmar diesel powering the yacht at up to 10 knots. Because sometimes, alas, you really do need to be home by Sunday night.
Layout & Design
One word sums up the layout and design of the LM46: Soul. Too many boats built and bought today lack this key element, but by carefully considering every aspect of this new yacht – including the hull material itself – boatbuilders Cabot and Heidi Lyman and yacht designer Kevin Dibley have created a boat that is ingenious in its simplicity, efficiency, and performance.
The spacious cockpit features 6’5″ seats, ideal for accommodating guests or, when the weather is right, a night of sleeping under the stars. Twin helms offer unrivaled visibility, while the drop-down transom affords no-step access to and from the dinghy. All sail-handling is easily managed without ever leaving the cockpit.
Step below and enjoy a seat in the spacious salon and take in the V-groove overhead and Herreshoff-styled bulkheads and trim – you’ll instantly find yourself transported from your daily life to somewhere quieter, simpler, more elegant. The wraparound galley, designed using the lessons Cabot and Heidi learned during 16 years of living on their boats around the world, is as appropriate to preparing a three-course dinner as it is for mixing up a batch of evening cocktails. The aft full berth makes for a welcoming guest cabin or, when offshore, the ideal sea berth.
Moving forward, to starboard you’ll find a separate head with vanity and shower. The huge forepeak includes a centerline queen bed, allowing access from each side, and storage for a weekend or a month’s worth of clothes and gear. Here, as everywhere aboard the LM46, you’ll be struck as much by what you see as what you don’t – we’ve included everything that you need and nothing that you don’t (watermaker, A/C, excess electronics).
Recognizing that every crew has unique needs and desires in their family yacht, the LM46 is available in three cabin configurations and two keel options. The single aft cabin version allows for a huge lazarette to starboard, while a second head option shifts the aft cabin to starboard and still allows for a cockpit locker. The double aft cabin version offers the most interior accommodations of all. At just 6′ draft, the shoal keel version allows the yacht to explore shallow anchorages, while the deeper 7’7″ keel increases performance even further. For those seeking to take it up another notch, we also offer a 10′ draft version.
LM46 Mock-Up Tour
Lyman-Morse Founder Cabot Lyman walks through the LM46 full-size mockup and explains some of the design considerations included in this breakthrough performance cruising yacht.
Construction
The LM46 uses modern design and technology to improve upon the most sustainable building material ever created: Wood. Wooden boats 70 years old or more are still winning offshore and coastal races, sailing over many horizons, and, when necessary, are far easier to bring back to life after years of neglect. The Douglas Fir and Western Red Cedar planks that comprise the LM46’s nearly 1”-thick hull are sustainable, originating from sound growth- and forest-management plans and thousands of years of experience. Using the cold-molded building process results in a hull that delivers a quiet ride underway and is both flexible and incredibly strong. A layer of glass on the topsides increases durability and reduces maintenance. Wisely employing modern building materials and techniques and eliminating excess electronics allows us build a low-maintenance yacht that breaks the cycle of having to travel from boatyard to boatyard to keep a yacht in top condition – an ironic claim for the owner of a service yard to make, we’ll admit!
Lyman-Morse’s intelligent use of its Haas GR712 Computer Numerical Control (CNC) machine to cut planks, bulkheads, and joinery reduces costs for the hull and deck construction, but we have not thrown out the baby with the bathwater in the LM46. The cockpit, deck, and cabinhouse, often the site of water-infiltration in older wooden boats, feature a composite structure that keeps things bone-dry belowdecks. To use anything other than modern materials in these locations would be irresponsible.
Whenever possible, all items for the LM46 are built as modular units outside the boat – the same system used by wooden production boatbuilders half a century ago and somehow forgotten. We use such time-tested processes, combined with expert Maine shipwrights and high-tech tools such as lasers and 3D printers, to create a construction plan that is competitive with production boats but that yields a yacht that is meaningful and carefully constructed – a world apart from the fiberglass cookie-cutter boats that fill marinas and boat shows these days.
Click here to see photos of LM46 hull No. 1 during construction at Lyman-Morse in Thomaston, Maine.
Sails & Rigging
Fully battened squaretop main
Asymmetrical spinnaker (optional)
Staysail (optional)
Code Zero (optional)
Mast – Aluminum or carbon (air clearance of 63’10” allows access under ICW bridges)
Sail handling:
Primary and secondary sheet winches, easily reached by helmsman and crew with the ability to stand and grind without leaving the cockpit
Halyard winches – Manual or Electric (optional), also used for reefing lines, located on cabinhouse top
Spinlock jammers/clutches
Feathering propeller by MaxProp
Isotemp hot water heater (plumbed to engine)
Force 10 propane stove, with Trident controls and detector
Espar heater (optional, for those in higher latitudes)
Jabsco pressure water pump
Lewmar low-profile deck hatches
640AH Lithium Phosphate batteries (optional) for unlimited cycles
44 lbs CQR anchor, equipped with 20’ of 3/8″ chain and 150’of 3/4″ Yale Brait anchor rode
Lewmar anchor windlass
Blue Seas electrical panel at navigation station, with 12VDC and 110 AC breakers
Isotherm refrigerator/freezer, with evaporation plates
Polar stainless double galley sink
Scandvik faucets
78-gallon custom stainless water tanks (2)
81-gallon custom aluminum fuel tank
Polyethylene Vetus holding tank
Tecma marine head
Life preservers (optional, Spinlock vest-type)
Sailing instruments
Navionics plotter on GPS-enabled iPad
Broadband radar -12-mile range
LED lighting throughout
Marelon seacocks by Forespar
120-amp engine alternator
Jabsco anchor washdown pump (optional)
Groco Sea Strainers
Centek muffler, with stripper for silent charging
4″ blower for engine compartment
Scott vented loops
Rule and Whale automatic bilge pumps
Whale manual bilge pump (near helm)
Seadog deck fills and pumpout deck fitting
Perko hinges
Cushions – mid-density foam with ultrasuede covers on seats, canvas on berths
Reconnecting – Family Sailing
The LM46 doesn’t deny the “real” world – it puts it in perspective.
More than 170,000 miles of sailing together, including a three-year circumnavigation with their three boys and numerous offshore races and trips to the Caribbean and the South Pacific, has shown Cabot and Heidi Lyman one thing: Boats have become too complicated. As the founders and owners of the world-renowned Lyman-Morse Boatbuilding Company for the past 43 years, they’ve built over 110 vessels, many of them equipped with watermakers, in-boom furling, and digital screens of all shapes and sizes. For many of us, all that gadgetry just distances us from why we started sailing in the first place: Reconnecting to a simpler way of life. Our day-to-day lives have become consumed with devices, passwords, and updates. Over time, our boats have tried to keep pace instead of providing an escape, a place where you can forget the world and simply enjoy. The LM46 changes that.
Spectacular in its simplicity, powerful in its performance, unparalleled in its quality. Contact us today and make the LM46 a member of your sailing family.
The Company offers the details of this vessel in good faith but cannot guarantee or warrant the accuracy of this information, as components are subject to change. A buyer should instruct his agents, or his surveyors, to investigate such details as the buyer desires validated. This vessel is offered subject to prior sale, price change, or withdrawal without notice.
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Boat Building in "Cold Moulded"
Moulded Ply or Veneer
From full size patterns supplied with the plans , station frames are marked and cut out of scrap timber and plywood. Stringer positions are marked and notched. The frames are erected on a prepared strongback and the stringers, keelson and stem are added.
Very little fairing off is necessary as the stringers go in at the correct angle and allow the plywood or veneer strips to be added glued and nailed to the stringers.
The plywood or veneer strips are applied diagonally and sometimes vertically and fore and aft as shown in the plans.
BUILDING TIP: When installing veneers or other material that requires temporary staples, one of the most onerous jobs is removing the staples. Many methods have been tried but this one successfully used by Russ Stevenson works well....buy some narrow THIN packaging METAL tape and this can be used underneath the staples....easy to remove when the glue has set...simply give a hefty tug on one end of the tape and the staples come out without a whimper...make sure to wear goggles as staples may fly in all directions.
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Custom cold-molded wooden boat construction The 34' Odyssey
$ 0.00 0 items
Carolina 25
$ 750.00 – $ 4,750.00
The Carolina 25 is a classic North Carolina sport fishing boat design in a trailer-able center console layout. This design features the famous Carolina flare, broken shear and tumblehome that is sure to turn heads. This boat is built using the cold molded method and best suited for those with boat building or woodworking experience.
Looking for more photos? Want to connect with others who have built this boat? Check out the Salt Boatworks boat builders group, HERE!
Boat Plans include prints detailing assembly of the boat and full size templates to trace and cut all jig parts.
Jig Kit includes prints detailing assembly of the boat, plywood jig parts CNC cut, and HIN assignment.
NOTE: Jig components include stringers, transverse frames, bulkhead, transom, stem, bracket plus temporary structure. We do not include all plywood like the FRS series because hull side and hull bottom are cut to fit during assembly using the cold mold method.
Jig Kits are shipped by motor freight or can be picked up from Morehead City, NC. Shipping will vary by destination and you should contact us for a quote BEFORE placing an order if you plan to have the kit shipped. Some ball park costs from past shipments are ~$600 for South Carolina and ~$800 for southern Florida and Texas.
Orders placed here can only ship within the USA at this time. If you are outside of the USA, please send us a message on our contact page for a shipping quote.
Description
Additional information.
Reviews (1)
Our Carolina 25 is a classic North Carolina sport fishing boat design in a trailerable center console layout. This design features the famous Carolina flare, broken shear, and tumblehome that is sure to turn heads. The bottom shape is that of a traditional “Carolina” bottom with 18 degrees of dead rise aft and a sharp V at entry for a smooth and efficient ride with stability at rest. There are no interior compromises either, a single level floor all the way forward and a large single fuel tank which allows a step down inside the console makes a spacious and easy to navigate interior. Powered by single or twin engines this boat will take your family to the sand bar or off shore to the fish!
This boat is built using cold molding and is recommended for those with boat building and/or wood working experience. Available as a pre-cut jig or full size patterns, both options include detailed assembly drawings, making it easy to build a boat of your own.
28’0″ LOA (including bracket)
25’2″ hull length
8’6″ beam (trailer-able width)
18 degrees dead rise aft
17″ hull draft @ 6000 lbs
140 gal fuel capacity (single tank)
350hp (30″ shaft) or twin 200hp (25″shaft)
Cruise 30-35mph, single 350hp runs ~40mph and twin 200hp runs ~45mph
Single level / flat deck full length of the hull
Can be built as a center console or express with cabin
Bottom : 12 sheets of marine grade plywood 3/8”x4’x8′
Sides: 18-20 sheets of marine grade plywood 1/4”x4’x8′
Floor & Gunnel: 8 sheets of marine grade plywood 1/2”x4’x8′
Ceiling: (optional) 7 sheets of marine grade plywood 3/16”x4’x8′
Keel: Fir – 6 boards 2”x4”x8′
Stringers: Fir – 4 boards 2″x6″x16′ (board)
Sheer: 200 linear feet of Juniper or Fir 3/4”x1” & 100 linear of Juniper or Fir at 1/2”x1”
Rib Bands: 180 linear feet of Juniper or Fir 3/4”x1”
Chine: 250 linear feet of Juniper or Fir 3/4”x3” OR 3/4” marine plywood cut in 3″x8′ strips
Sheer Bumper: 140 linear feet of Fir or Sapelle 1/2”x1-1/2”
Spray Rail: 50 linear feet of Fir or Sapelle 3/4”x1-1/2”
Floor Supports: 200 linear feet of Juniper or Fir 1.5”x1.5”
Resin: 30 gallons of marine grade epoxy resin (DO NOT USE POLY OR VINYL ESTER RESINS)
Glass: 250 linear feet of 1708 bi-axial fiberglass 50” wide
Filler: 5 lbs of fumed silica or similar for fillets
Questions about Boat Building? Check out our FAQ
Weight
1 lbs
Dimensions
N/A
Kit Includes
CNC cut plywood, Prints detailing assembly of the jig, Plywood and dimensional lumber selection guide
Carolina 25 Option
Boat Plans w/ Patterns, Boat Jig Kit
1 review for Carolina 25
Kyle – October 10, 2019
I am a couple months into this build and can say that the plans are very well thought out and precise. One of the major advantages of these plans is that you will have most of the flooring framework done as well when fully assembled. There is a LOT of cutting for this jig, but it is a 25′ boat with a bracket. You can save about 80 hours of cutting by ordering the pre-cuts. So far I remain impressed and excited to get her done.
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05-11-2016, 16:33
.
I hope this thread will serve to educate and stimulate discussion and knowledge about this form of construction. And, I hope you will enjoy about these as I have.
In this thread I will post photos and descriptions of boats I find that are Cold Moulded (CM). This may take some months, so this will be an "ongoing thread" or evergreen discussion that will contain examples of boats, links to information about the CM process, opinions from owners of CM boats, photos of CM boats I find and generally anything about CM boats. CM boats are relatively rare, so you may see this thread get in the for a while, then pop up again when I find a new CM to display in this exhibition. I will continue to post what I find as I find it.
I am not an expert on CM building. I am simply fascinated by it, and consider it interesting as a method of boat building. That is my personal view, and one reason why I would own a CM boat. I encourage any CF members who own a CM boat to address the likely technical questions, and I will defer to their knowledge on technical issues. Consider me a guide or curator of the exhibition.
I encourage any CF members to participate and to contribute to this thread. Feel free to post your own finds, your own CM boats (photos please), your own anecdotes about your experience with CM boats, or anything you find interesting about CM boats.
are for Illustrative Purposes Occasionally I will post photos and a link to a boat that is listed (at the time posted) , but I have no financial connection to that boat or any boat or seller. I use these photos and descriptions because they are accessible and pertinent. I am not selling these boats. I am merely sharing information about boats I find and I post the link to help others here on CF who may be looking for a boat like the ones I find. I hope it helps others, that is my primary reason for doing it (and because I don't have time to answer requests for links to where I found the photos or boats). I do hope if someone does buy one of these boats, that they will then post some photos of it sailing or tell us about it. Just remember I am not an expert on these and as I always say: "Caveat Emptor."
I hope you enjoy this thread and if you do, subscribe to it so you will see the boats I post over time. It is simple to subscribe to a thread, you simply use the drop down Thread Tools menu or simply post a comment in the thread and you will be automatically subscribed.
I mention this because due to the more rare nature of the topic boats.
And as I have learned while looking for relatively rare boats, The best opportunities go fast, and I have missed more than a few.
Fair winds to all! _______________
05-11-2016, 16:38
to Cold Moulding a Boat
The following link is the best example I have seen to quickly introduce you to the process of building a CM boat. I encourage you all to view the site via the link to learn or just to see another boat build. Pictures tell the story better than I could. ____________
If you are interested in wooden boat building techniques like Cold Moulded (CM) boats and would like to see a recent build, then follow the link to see MANY photos showing the entire build process as this Cold Moulded schooner takes shape. The photos show the CM process very clearly, and also show the casting of the lead ballast and the fabrication of the Carbon Fiber masts too. All together, it is a fascinating picture story of how this boat went from to design (plans) to finished boat in the . I enjoyed seeing it and I hope you will too.
This blog post is lengthy but has many photos, good captions, and good descriptions of the entire process. It is one the better descriptive pages I have seen for a boat build, and exemplary for detail and easy viewing as simply scrolling down the long page is a quick way to see the entire process from plans to splash.
____________________ Here are some excerpts from that linked site:
Actual march 2015
Design : Nigel Irens
Cruising sailing boat
type : long keel/centerboard
type : schooner gaff rig
: 14.97 meter
Beam : 4.2 meter
: 1.68 meter ( 3.2meter down)
Displ. : 21 metric ton
Excerpt: "As per Lloyd’s regulation will be 40mm thickness, in strip-planking/cold molded , with yellow meranti for the strip and two layer in diagonal of Philippine mahogany (red dark Luan) kiln dry, all the hull is completely encapsulated with bi-directional , we use local type PRC#7 who was formulated by the U.S. many years ago when they still had bases in the ."
05-11-2016, 16:43
really does grow on trees and when sourced from sustainably managed forests, it can be an environmentally responsible material. If you can keep it dry it can have excellent stiffness to weight ratios and also has very high cyclic fatigue resistance.
I would like to see the topic expanded from just cold-molding to the umbrella term of "wood composite construction" which would include strip plank and tortured as well since these techniques have many virtues onto themselves and sometimes form sub-structure for additional veneer laminations more normally associated with cold molding.
05-11-2016, 16:55
as well since these techniques have many virtues onto themselves and sometimes form sub-structure for additional veneer laminations more normally associated with cold molding.
05-11-2016, 17:19
and chemical resistant, epoxy is well suited for encapsulation of wood which means by depriving wood of water and oxygen it will not . Better still, by keeping it dry you allow it to retain it's maximum stiffness. A highly sought after quality for a boat building material.
Here is a of a "hot molded" boat ready to go into an autoclave-
05-11-2016, 17:22
05-11-2016, 17:55
the Autoclave and description and the Gougeon Brothers ("G Bros") Epoxy Book or "WEST Sytem" bible. Good additions to this thread.
05-11-2016, 18:08
designed . One of the early Gougeon Brothers projects that put them on the map. Winner, 1975 Cup. She was "retired" to Lake Champlain and raced hard for 20 years, totally dominating the very competitive local phrf fleet.
05-11-2016, 18:24
designed . One of the early Gougeon Brothers projects that put them on the map. Winner, 1975 Cup. She was "retired" to Lake Champlain and raced hard for 20 years, totally dominating the very competitive local phrf fleet.
05-11-2016, 18:29
Boat: Nauticat
I seriously considered this one once:
Some great pics of the construction process there.
Newer Perry design.
05-11-2016, 18:33
Boat: TRT 1200
05-11-2016, 19:53
Boat: Jon Sayer 1-off 46 ft fract rig sloop strip plank in W Red Cedar
05-11-2016, 20:09
Boat: Catalina 470
05-11-2016, 20:15
05-11-2016, 20:16
Boat: Currently Shopping, & Heavily in LUST!
designs, such as his Tiki 38'.
On her construction, it's pretty common to have horizontal strips incorporated into a cold molded boat. As it's a quick way to add a lot of wood to her without needing another 3-5 layers of veneers, & concomittantly requiring the insertion & of several million more staples. It's also a better way to do things from the perspective of needing a lot less epoxy. Which of course also reduces costs, along with the less layers & staples thing.
I'm certain that we'll never know the true cost of building this boat, but I'm still curious. Ditto on wondering why she has so few berths, & how this works for making? Regardless, I want one!
Edit: Jim, I'm sure those hollows aid in keeping I2's decks a bit drier, & her ride a touch smoother The Uncommon Thing, The Hard Thing, The Important Thing (in Life) Making Promises to Yourself, And
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Projects: Building with the cold-moulded method
After an unfortunate motorbike accident, Harry Evans was forced to put his boating career on hold. However, an opportunity to train as a boatbuilder at the Boat Building Academy in Lyme Regis has given him a fresh start. Here, Harry tells us about his work at the college to build a Clinker sailing boat, which he’s called ‘The Last Leg’.
How did the project come about?
Building a boat is a key part of the training here at the Boat Building Academy Lyme Regis. It was such an exciting prospect to get back into the practical side of things after the accident.
The Last Leg was initially intended to be a traditional Clinker. However, to make things more interesting I decided to build it using the cold-moulded method of construction.
Which WEST SYSTEM® epoxy products did you use? How did they help?
I used WEST SYSTEM epoxy products throughout the build, as I believe they’re the most efficient and reliable.
The WEST SYSTEM 30kg C pack plus the corresponding pumps were great. The pack gave me both 105 Epoxy Resin® and 205 Fast Hardener® , while the easy-to-use pump system was quick, accurate and took the guesswork out of time-pressured college tests.
I also used WEST SYSTEM 406 Colloidal Silica – it’s a fantastic thickening agent, very strong and hard.
The WEST SYSTEM 409 Microsphere Blend low density filler was easy to use and shape. Finally, I used WEST SYSTEM 740 Glass Fabric , a 135g/m² plain weave glass cloth which is essential for water-tightness, strength and resistance to abrasion.
What did you learn about the cold-moulded method whilst doing this?
I would definitely recommend giving serious consideration to cold moulding and epoxy as a construction method – it’s fast and very strong. For a start, the cold-moulded method was a lot quicker than the traditional method of Clinker construction; we managed to fully plank the hull and have it watertight in approximately three weeks. What’s more, you can really see how lightweight and strong modern epoxy-wood methods are. Using epoxy enabled us to create a smooth hull with a monocoque structure, eliminating the need for through-hull fastenings and calling for fewer reinforcements. All in all, compared to traditional methods, the cold-moulded method is very satisfying, relatively trouble-free and produces a low maintenance boat that will have a long life in the water.
What was the most rewarding part of the project?
It was incredible to see how fast and strong the cold-moulded wood-epoxy method can be. It was also great to be working as part of a team. We are all looking forward to finishing the boat and seeing it in the water.
What’s your top tip for boatbuilders looking to start a similar project?
Manage your time well and source materials that you can trust – make sure you do your research. Apart from that, just go for it!
Our thanks to Harry Evans for his contribution. You can learn more about the Boat Building Academy at Lyme Regis on their website .
Do you have a project that you’re working on? Email us at [email protected] and we could feature it in a future edition of epoxycraft!
Want to know more about the products mentioned in this article, including the full range of WEST SYSTEM epoxies? Visit the WEST SYSTEM website .
Back to projects
G/flex® 650 vs. 655: Choosing the Right Epoxy Adhesive
Swiss Couple’s Boat Restoration Rescue?
What Can You Do With a WEST SYSTEM® Epoxy A Pack?
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Our Construction Process
The crew, well versed in old-world craftsmanship and building techniques (the skill-set that is at the foundation of Van Dam Custom Boats), also embraces technology and innovative design as an integral part of the future of custom wooden boat building.
Technology, at the hands of a master, will not strip away the intricacies of custom handworkings in wood, but will assist in making it last longer and perform better. A balance is reached between function, performance and beauty. Our processes envelop them all.
Wood Composite Construction
It has been called a master craftsman’s art form. At Van Dam Custom Boats, we use the process of wood composite construction to build all of our one-in-the-world watercraft. This process involves the utilization of epoxy adhesive to laminate many thin layers of wood together – creating the hull and structural elements of our boats. By marrying legacy craftsmanship with sound engineering principles, we are able to construct vessels that are stronger, lighter and more durable than boats built via other methods. Van Dam Custom Boats are built for generational enjoyment and constructed to stand the test of time.
In the design phase we shift from 2D drawings to 3D virtual models, using state-of-the-art 3D computer aided design (CAD) software to detail every inch of your boat. Propulsion, systems and construction details are married with style and concept. There’s still plenty of creative work to be done here as the space evolves and design opportunities present themselves.
Systems Design
Every Van Dam boat requires its own unique systems package to meet the owner’s expectations of performance, function and capability. Whether it’s Garmin, C-Zone, Humphree, Seakeeper, Volvo or future technology, we design, program and thoroughly test each system to ensure they complement one another and operate in unison.
Innovations
At Van Dam, we continuously explore new horizons in recreational boating. Drawing inspiration from the automotive, aviation, and marine sectors, we integrate cutting-edge principles of design, engineering, and construction into our projects. Whether it’s pioneering digital switching systems, wake-adapted rudders, or advanced lighting solutions, we have the expertise to turn innovative ideas into reality.
Hand Cut Lumber
Every board that goes into our custom builds is craftsman selected and carefully sorted by characteristics that will dictate whether it is used for structure, cosmetics, or in some cases both. Each is hand cut and hand bent per design specifications, while attention is given to book matching the grain throughout the construction. Our wood is used as a unidirectional fiber as it is much stronger along the grain than it is across the grain. Engineering takes full advantage of this characteristic and while such precision takes time, it is what separates a Van Dam Custom Boat from others in the industry.
Artistry and functionality carry over to our metalwork, with intricate craftsmanship being a company wide offering. From hand polished cutwaters to custom shaped seating and framing adornments, all metal work is skillfully created on site. Design revisions, or improvements to performance, are made at the hands of our metal craftsmen, utilizing their natural talents and the state-of-the art equipment at their disposal.
Paint & Varnish
Finishing the areas of each boat that will rarely be seen, with the same care and meticulous standards as our mirrored exteriors, is one of many attributes that sets Van Dam Custom Boats apart in the world of custom wooden boat building. It not only guarantees the longevity of quality and function, it affords you peace of mind – your commission is of top-of-range craftsmanship, inside and out. It is not about simply finishing the build and moving on to the next project. It is about you, your expectations and your future enjoyment on the water.
We are no less meticulous in our approach to mechanical and electrical component construction. Power, performance and ease of use are integral aspects of your boating experience and Van Dam Custom Boats recognizes this area as a craft unto itself. Master Certified craftsmen in systems and electronics create and assemble the perfect inner workings, allowing you to control your boat effortlessly, safely and with confidence.
Pay attention to the details.
Do the little things right so the big things work out.
The best place to go with your idea for a dream boat is Van Dam Custom Boats. We were impressed as much with the total experience as we were with the end result. WOW’s on and off the water.”
– Chocolate Chip 3 Owner
THE GOUGEON BROTHERS BOATS
Cold molded boat construction.
The Gougeon Brothers began experimenting with boat building while they were kids growing up near the Saginaw Bay. As young adults, they developed a novel boat construction technique based on laminating wood veneers with their proprietary epoxy formulation. Their strong, fast sailboat started winning regattas, leading other competitive sailors to commission them to build a number of high-profile racing sailboats, both monohulls and multihulls.
Let’s take a look at some of the boats the Gougeon Brothers have built over the years.
Sailing Barge
It is no exaggeration to say that the Gougeon brothers engaged in building experimental sailboats their entire lives. In the summer of 1947, Meade adjusts the (literal) sheet while younger brothers Jan and Joel look on.
DN Iceboats
Living in Michigan, “hard-water sailing” is one way to extend the season. The narrow fuselage, rigging, reduced friction, and sailing angles of DN iceboats (designed by Arrol, Lodge, and Jarret for the Detroit News) would heavily influence all of Meade and Jan Gougeon’s boat designs.
The Gougeons’ first commercial enterprise was building DN iceboats.
DN 1195 Photo credit: Henry Bosset
Meade was living in Erie, PA when he built his first trimaran. He called it E1 for “Experiment number one.” He considered this 1963 multihull “a disaster” and didn’t have a lot to say about it, other than it had “too many moving parts.”
Meade’s constructed his second experimental trimaran, Pencil , under an apartment carport in 1964. Built much too light, Pencil broke under her own weight shortly after her launched.
Wee Three II
This was Jan’s second version of his Wee Three design (not pictured). The lee ama broke clean off of the original . In 1965, Jan built Wee Three II to be sturdier, and to meet IYRU Class-C rules. Note that she is rigged with a wingmast, much like a DN iceboat.
Omega , a 25′ trimaran built in 1965, was the first boat the brothers designed with articulating amas. This experimental trimaran performed very well at Yachting magazine’s One-of-a-Kind Regatta in 1965. This success on the racecourse brought notoriety to the Gougeon name in multihull circles.
Meade Gougeon designed and built Victor T, which he launched in 1969. At just 320 lbs, she earned the distinction of being the lightest Class C competitor in the 1969 Nationals in Hamilton, Ontario. There, Victor T took home the win against a strong field of wingmast-powered catamarans.
Back in the day, budgets were tight so Meade repurposed the sails he’d used on Omega (above).
Launched in 1970 and pictured here in 2018, Meade Gougeon’s 35′ trimaran Adagio was the first large, all epoxy bonded and sealed wooden boat built without the use of fasteners. Meade and Jan Gougeon constructed her in just six months. She’s been sailing on the Great Lakes ever since and continues to be a serious contender in the Mackinac races.
Adagio is proof that epoxy-bonded monocoque structures can last for generations.
Golden Dazy
Another notable cold-molded boat: the Ron Holland-designed Golden Dazy . Launched in 1973, she won the 1975 Canada’s Cup . The success of these wood/epoxy composite boats led to a “mini-revolution” amongst builders and designers. They realized that they could build stiffer and stronger hulls with wood and epoxy than they could with fiberglass, and do so without increasing the weight. Many custom builders continue to choose wood and epoxy as their construction materials today.
Built in 1976, Hot Flash was a cold-molded, fast, half-ton racing monohull designed by Gary Mull. The Usnis brothers, who sailed out of Detroit’s Bayview Yacht Club, commissioned the Gougeons to construct her with wood and WEST SYSTEM Epoxy. The boat was later rechristened Boomerang .
In 1977, the Brothers built Rogue Wave , a Dick Newick-designed trimaran, for Phil Weld to race in the 1980 OSTAR challenge. Unfortunately, a rule change meant Weld never got the opportunity. This impressive 60′ cold-molded trimaran was among the larger boats the Gougeon brothers built.
Photo credit (right): Polly Brown
The Gougeons launched the 60′ proa Slingshot in June 1978. Commissioned by Georg and Carl Thomas, Slingshot competed in the 1979 speed trials in Weymouth, England, recording the second-fastest speed. Racing the ditch in Texas City, Texas in 1980, the crew posted a speed of 38 knots.
Unfortunately, Slingshot came loose from her mooring during a storm and got destroyed when the waves dashed her against the rocks. A salvaged section of her bow still hangs in the Gougeon boatshop
Slingshot’s crew included Jan Gougeon, Mike Zutek, Ron Sherry, and Olaf and Peter Harken.
This 1979 Gougeon-designed and built wooden cruising trimaran capsized in the Atlantic in 1980 during a qualifier for the OSTAR challenge. Sailing solo, Jan Gougeon spent four long days in Flicka’s capsized hull. He had plenty of time to think about rightable trimaran designs before a passing freighter rescued him. Flicka had to be abandoned at sea.
Read more about Flicka’s capsize at Epoxyworks.com.
Jim Brown designed this 27′ freshwater trimaran and longtime GBI Technical Advisor, Captain James R. Watson built her in 1979. Watson elaborates:
This boat sports an experimental wingmast constructed of 1/16″ thick aircraft birch plywood outer skin, 1/64″ thick plywood inner skin separated with 1/2″ Tricell H™ (resin impregnated paper) honeycomb. It was fitted to the boat five years after initial launching. With some reinforcing stringers, this laminate stack was lightly vacuumed while flat, then folded and placed into a form to establish an airfoil until all cured. James R. Watson, Wood/Epoxy Longevity , Epoxyworks 17
Photo credit (left): Janet Townley
In 1980, Jan began building Splinter . Following his terrifying experience aboard Flicka , he designed this developed plywood trimaran to be rightable if capsized. Splinter was the second boat, after Adagio, the Brothers launched with a wingmast. Pictured (at right) in 2019, she still competes on the Saginaw Bay against other noteworthy Gougeon-built multihulls including Adagio and Ollie.
Named after the Gougeons’ grandmother, Ollie was started in 1984 using the Gougeon brother’s developed plywood technology. The design was trademarked as a Stressform™ 35 along with Stressform wingmast plans. Ollie’ s design further advanced Jan’s ideas for self-righting multihulls.
Jan was always thinking of the next boat and had an appetite for solo sailing. After the Atlantic capsized of Flicka , every boat he designed was self-righting. Ollie (right) acing on the Saginaw Bay in 2019.
Adrenalin is a Formula 40 Trimaran with articulating amas. GBI built her for Bill Piper of Ossineke, Michigan in 1987. This boat amazed the sailboat racing world by taking an extremely close second place during her first regatta: the Formula 40 Grand Prix circuit in Brest, France, in April of 1988.
A Formula 40 rule change later legislated Adrenalin out of contention.
The G-32 is an innovative 32’catamaran designed and built by the Gougeons in the early 1990s. These production boats feature a water-ballast system, are self-righting, and are trailerable. The masthead float doubles as a wind vane and prevents the boat from going completely upside down if capsized.
The Gougeons conceived the G-32 as an affordable cruising and racing vessel but it didn’t achieve market success in the short time that it was produced. The fourteen that they built are still racing and sailing today.
Meade and Jan’s first powerboats were these 32′ Gougmarans launched in 2007. Based on Dick Newick-designed hulls, the brothers conceived these comfortable shallow-water cruisers for stability, low wetted surface, minimal wake, and excellent fuel efficiency.
Read more in Birth of the Gougmarans at Epoxyworks.com.
Chris Beckwith designed the i550, an 18′ stitch-and-glue sportboat. The Gougeon Brothers built Hot Canary in 2011 and raced in the Everglades Challenge.
She is now under new ownership and has been renamed Vivacious . Read the story about how her new owners refit her for camping/cruising .
Jan Gougeon’s final boat project was Strings , a 39’7′ “folding cat with a fuselage. He launched her in 2011. She has long, narrow hulls and a center cabin that rides above the water. An elaborate network of lines (aka strings ) makes this ingenious boat perfect for solo sailing.
Although Jan passed away in 2012, Strings sails on, competing in regattas on the Great Lakes.
Elderly Care
This was the last of several boats Meade designed and built for competing in the grueling, 300-mile Everglades Challenge. An outrigger sailing canoe, Elderly Care provided accommodations for Meade to sleep at night and race during the day. His tactic worked: He place first in his class in the 2017 Everglades Challenge just five months before he passed away at age 78.
The Gougeon Brothers’ experiments in boat design
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The Principles:
Laminating multiple layers of that core (in this case plywood)
In alternating directions
Forming a monocoque structure (key point)
It is for waterproofing as it encapsulates the core, inside and out.
It also provides some degree of abrasion / penetration resistance.
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Cold-Molded Boats good or bad?
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Welcome aboard. A well built cold molded boat will be light, stiff, and durable. But they were mostly built for racing, and they represent a very small percentage of the market. Glass boats built in the 60's tend to be heavy, therefore solid, and less prone to blisters than 80's boats. But older boats often need much work: new rigging, interior or engine. You really should read this site thoroughly and spend time with sailors and aboard boats before you buy one. Good luck, it's a great lifestyle.
Cold molded boats are great! There are few because they're labor intensive to build.
I believe that Bruce Schwab's "Ocean Planet" has a cold-molded hull. Managed to complete the Vendee Globe in 2005.
For a one-off boat my first choice would be aluminum and my second choice would be cold-molded with epoxy construction. They are in the minority because they don't lend themselves to series production. But they are lighter and stronger than a conventional fiberglass boat. This is where fiberglass wins - one mold and they can pop out hundreds if not thousands affordably. As with any boat you find maintenance is more critical than hull material.
Ocean Planet is cold molded. I sail a cold molded boat, and if ever I was to build a boat. I would use the process. I am very happy with her. You do have to be careful of fresh water, and I have had a couple of small drainage problems. You don't have to be an artist to do a good fix, and the repairs can be easy. Make sure to get a syrveyor who is familiar with the construction....... i2f
Not always, there are different composites....... i2f
A cold molded boat is a boat with a laminated wood or fiberglass hull. The wood is cut into thin strips about 1/8" thick. these are then bent over frames on a diagonal to get the hull shape. Subsequent layers are added with epoxy resin, on the diagonal running the opposite way so they cross. Essentially the hull becomes a single thick piece of plywood. There is a fiberglass material made in strips called C-flex that is also used to build a boat the same way. You don't need a mold, so it is good for a one off. However you don't get a molded smooth gelcoat, so finishing the hull is very labor intensive.
Ah thank you..great info..so its pretty much the same as cold molded then?
In all due respect, there is some confusion here. A cold molded boat can be any combination of wood venners or wood veneers over strip planking. There is no one recipe for a cold molded skin. If you putn a core of foam beween cold molded skins then I would call that a "composite" boat. That is a very good way to build. As for longevity: My cold molded NIGHT RUNNER just won it's class and was First Overall in the Swiftsure Race this weeekend against some very fast and fancy competition. NIGHT RUNNER is 35 yers old!
Thanks Bob, congratulations on the win.
Star: Thank you. I lied. NR is only 32 years old.
I should correct myself. NIGHT RUNNER is only 32 years old. But it has been around Cape Horn and it has plenty of miles on it.
LOL, well, she's practically new! My strip planked ketch (designed by WD Knott) is 43 years old, but I can't imagine she ever won any races. Her design very traditional (enlarged from the 36' gaff schooner Aries). But she's also tight and sound.
Here's a pic of NIGHT RUNNER. Her nickname in Seattle racing circles is THE MAYFLOWER.
Attachments
Maestro, You are the client. You have no budget restraints, within reason. What is your choice of hull material ? Don't go all exotic on me. Now Fuzzballl is the client and fuzzball has no budget restraints. I really do like the idea of aluminium but ending up with a hull that looks as pretty as NightRunner would probably sway me to cold moulded.
Wombster: I'd go grp with a foam core. No question.
Interesting Bob. What is your second choice?
I think I have seen the wood one around a bit. Possibly in the woody section at opening day this year. Pretty boat. Not that I have had one, but a foam core hull would be on my top of th elist, if nothing else, altho I could be wrong, but from an insulation stand point, light wt, and there should be no issues with rot like wood. But how I would love to have my little Glen-L 8-ball I built in r high at times......one of these days may I will build another, now there is a S&G version with a dagger board which I would have preferred over the CB version I had..........I digress...... Marty
My second choice would be wood veneers over a foam core. That is a great way to build a strong and light boat if you have the labor skill to do the wood part. JAKATAN, my 41' schooner, was built that way and its a crackerjack boat in everey way.
That's how Rage is built, isn't it? She has proven pretty durable - and fast!
?
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Is a Cold Molded hull Viable? Insurable? Safe?
Discussion in ' Boat Design ' started by JunkRat , Aug 5, 2021 .
cold molded
JunkRat Junior Member
Greetings. My past boat was fiberglass, it was pretty maintenance free-- I just cleaned it, replaced zincs and bottom paint and that was about it. But I just saw a boat that is cold molded and in every other way it seems like a fantastic boat. But I'm concerned about it being a "wood boat". Of course there is carbon fiber in some locations and strictly speaking it is a composite, but it uses plywood instead of fiberglass. How hard is it going to be to maintain? Is it possible to insure? Is it as robust/safe against groundings? I'm really out of my element here. If it were fiberglass I would be comfortable because that I know. From the listing: "Modern, wood/epoxy contruction is utilized, to achieve superior stiffness,strength and impact resistance...Top quality Brunzeelplywood,and West System saturation is used in the hulls, with structural cedar used in the stringers. Greenheart is used in structural beams and cockpit sole- because of its superior hardness." Would love to hear from owners of boats built this way!
fallguy Senior Member
Right now, insuring custom made boats has been hard. The market is saturated with production boats and the insurers have it made. I checked with one company and they insure self mades to about 26' iirc. stitch and glue composite boats are great, you need to be religious about overboring ply penetrations, refilling them with thixo, redrilling and sealing...and if you miss and hit ply, rebore and fill, etc...but they are light and stiff and fast to build any
Old Stoker Junior Member
Ragtime,the great racing ,hard chine plywood epoxy sailboat and this girl has been around,and still going strong,Stormvogel 80 of feet,plywood,Bruznel plywood.
comfisherman Senior Member
Call your insurance agent and start there. We have a wood boat fleet that has its own pool and it takes some doing to stay in it, but they seem to make it work. Cold molded has its fan base, clearly glass has dominated the market for a reason but cold molded has maintained a following despite all this.
Howlandwoodworks Member
I have a hot molded tiger striped mahogany 1954 Jet 14' class. The hot molding has never shown any rot. It seems to act almost like fiberglass. I was wondering if a vacuum press/infusion cold molded hull hold up as well? How far into the fibers does the epoxy penetrate? I just rebuilt the 4/4 Honduran mahogany centerboard trunk for my Jet this month. I would say it is 67 years old now and all of the hull material under the trunk is just fine. If I could get the durability out of a infusion cold molded hull that a hot molded hull offer I would be most interest in that process.
Howlandwoodworks said: ↑ I have a hot molded tiger striped mahogany 1954 Jet 14' class. The hot molding has never shown any rot. It seems to act almost like fiberglass. I was wondering if a vacuum press/infusion cold molded hull hold up as well? How far into the fibers does the epoxy penetrate? I just rebuilt the 4/4 Honduran mahogany centerboard trunk for my Jet this month. I would say it is 67 years old now and all of the hull material under the trunk is just fine. If I could get the durability out of a infusion cold molded hull that a hot molded hull offer I would be most interest in that process. Click to expand...
Well, I know this is a common method for custom and home builders, but this one was built by professional wood builders, in a production setup, but that production run only lasted for four boats. So they aren't very common. I asked my insurance guy and he asked me about home port and hurricane plans. So I'm not sure what's up with that. I'll hit him up again on Monday.
wet feet Senior Member
So nobody has any suggestions about the care that is needed? I see a couple comments about proper maintenance but none about what the maintenance is and how it differs from fiberglass.
JunkRat said: ↑ So nobody has any suggestions about the care that is needed? I see a couple comments about proper maintenance but none about what the maintenance is and how it differs from fiberglass. Click to expand...
Rumars Senior Member
Short answer : Keep it painted/varnished, keep it clean, don't screw anything to the boat unless you overbore and fill with epoxy. How long a paintjob lasts depends on how good it was done initially and the used paint. A good LPU job lasts like on any other fiberglass boat, 10-20+ years. Varnish can last long inside, outside is a function of location and brand. The boat must be kept clean, wipe the dust (don't let it bake to grime), keep the limberholes free, sponge the bilge, etc. Treat the entire boat like it's a balsa cored deck, use adhesive to attach things (superglue, double sided tape, 5 min epoxy), if you must use mechanical fasteners (like bolting something to the deck) overbore and fill. A cold molded boat is leak free by design, if anything leaks it must be taken care of. Hull survey is simple in theory, you have to find any and all soft spots, the problem if painted is that the current owner might not like it if you poke with an awl at his hull. The materials as advertised are top notch, but we don't know anything about the workmanship and previous care. Repairs consist of cutting the bad wood out, and scarfing in new wood. Insurance is a question for your local insurance broker. Groundings / abrasion depend on the original construction, we don't know how exactly how much and what type of materials are there. What we can say is that any abrasion must be repaired immediately so that water does not get into the ply. This can simply be a patch of fiberglass / some thickened epoxy, or a more involved thing, depends on the damage. Go see the boat, take a bunch of pictures, post them here.
I once drove to Wisconsin about 250 miles to see a cold molded Carver for sale. I got there and the hull had lost integrity from getting weather beaten. The way to check these hulls for integrity is to go up to the hullside on a trailer and pull on it. If the veneers have lost their ability to withstand some downwards and outwards force on the gunwhales (like a 100kg man pulling hard); they are done. The seller wanted $500 for the boat and I got there and told them the hull was shot and I'd give them 250 for the trailer and parts and cut the boat up. They accepted. I got some very nice hardware and broke even or came out ahead. I still have the trailer and use it in my yard weekly.
Skyak Senior Member
Skyak said: ↑ Cool! It sounds like my boat. What is the hull number and how did you find it's year? My boat was a derelict left in a yard in the Hamptons. The varnish was like potato chips so I didn't need any chemicals or heat to get to bare wood. It is safe to say that bare cold molded wood was exposed outdoors in salt air for no less than 5 years and the only loss to rot was an inch at the transom -to be expected because it was stored upright without a cover. Other than filling some gaps (less than 1mm) the hull is terrific in clear epoxy -like jewelry. Click to expand...
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rangebowdrie Senior Member
Howlandwoodworks said: ↑ How far into the fibers does the epoxy penetrate? Click to expand...
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The New Cold-Molded Boatbuilding
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It’s generally agreed that cold-molded construction is the best method for the amateur or independant professional interested in building a full-size cruising sail or power boat. A truly appropriate technology, cold molding combines the beauty of wood with the low-maintenance characteristics exceeding those of fiberglass. The New Cold-Molded Boatbuilding is the complete, soup-to-nuts presentation of process, with chapters detailing every facet of construction from choosing a design and setting up, through engine installation and wiring, to launching a design and performing sea trials. In addition, the author has streamlined the cold-molded process considerably, producing boats that are more economical, efficient, and sturdy–Boats built from native materials that will last the life of the builder and turn heads in harbours around the world.
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32 lbs
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12 × 12 × 1 in
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Description
by Reuel B. Parker Published by WoodenBoat Books 320 pages, lots of black & white photos and illustrations, soft cover. Copyright 2005, ISBN: 0-937822-89-2 It's generally agreed that cold-molded construction is the best method for the amateur or low-profile professional interested in building a full-size cruising boat. A truly appropriate technology, cold molding combines the beauty of wood with the low-maintenance characteristics of fiberglass. "The New Cold-Molded Boatbuilding" is the complete, soup-to-nuts presentation of this process, with chapters detailing every facet of construction--from choosing a design and setting up through engine installation and wiring to launching and sea trials. In addition, the author has streamlined the cold-molding process considerably, producing boats that are more economical, efficient, and sturdy--boats built from native materials that will last the life of the builder and turn heads in harbors around the world. Note: The Cold Molded process described in this book is similar but not the same as used in our designs. However, there is a lot of other helpful information such as joinery work, keel lamination, turning the hull, electrical, plumbing, finishing and more.
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COMMENTS
Construction Methods
Cold Molded Construction. Cold molded hulls have been built since the technique was used for World War II planes—often using casein or urea-based glues. Today, one would use epoxy almost exclusively, benefiting from its superior bonding, gap-filling, strength and water resistance. ... The pre-cut veneers (2-6 mm thick depending on boat size ...
The Advantages (and Fear) of Cold Molding
Brooklin Boat Yard has been building cold-molded boats since 1990. That first boat, a 55-footer for then-yard President Steve White, is still racing and looking good, Larkin says. It's evidence that cold-molded boats can be incredibly durable. "We've built 112 boats total," Larkin says.
LA 28: The modern trailable boat that's cold-molded from mahogany
Keel raised: 0.8-1.0m (2ft 8in-3ft 3in) Displacement: 1.5 tonnes. Ballast: 600kg (1,322lb) Engine: Torqeedo Cruise 2.0FP. Price: €120,000 (ex. VAT) The LA 28 is a beautiful, cold-moulded wooden ...
Cold Molding the Paine 15
French & Webb and Belmont Boatworks build the hull of the Paine 15 sailboat, designed by Chuck Paine. Video and narration by Chuck Paine.
LM46 Performance Cruiser
With a low-maintenance, cold-molded hull that offers the unmatched, comfortable motion and ambiance of a wooden boat with the 10-knot-plus speeds of a modern performance yacht, you and your family will form a bond with the LM46 that will last generations. ... Using the cold-molded building process results in a hull that delivers a quiet ride ...
Boat Building in "Cold Moulded"
Boat Building in "Cold Moulded". Moulded Ply or Veneer. This method of construction can be used to build several of our designs, and plans are available based on this technique. From full size patterns supplied with the plans , station frames are marked and cut out of scrap timber and plywood. Stringer positions are marked and notched.
Parker Marine Boat Plans
Parker Marine Boat Plans. PARKER MARINE ENTERPRISES sells Construction Manuals, Catalogues, Study Plans and Full Stock Plans. We do custom design work for construction in cold-molded wood, plywood, traditional wood, fiberglass, aluminum, ferrocement and steel. We do on-site or remote consultant work for new construction and major restorations.
Cold-Molded Carolina Boats
Cold-molded boats start off upside down and are flipped during the build process. Even as many custom builders embrace Computer Aided Design (CAD), Blackwell prefers to adhere to traditional boatbuilding skills. This builder starts by hand-lofting each vessel, which, in brief, means he makes to-scale drawings of each.
34' Odyssey: custom cold-molded wooden boat
This boat, like our other V-bottom hulls, was built using a stringer/frame system. In this system, transverse frames are erected, in this case on 20" centers. Over the frames go longitudinal stringers. The cold-molded planking goes over the stringers. In the photo, the frames are set up and faired, ready for the stringers.
The charm of wooden construction
Vicem, which recently consolidated all of its operation in Antalya, is practically synonymous with cold-molded construction. It has been utilizing cold-molded construction techniques since its first yacht—a 62-foot (19-meter) sailing ship, launched 20 years ago. The company recently celebrated its 20th anniversary by introducing the Vicem 100.
Build a Boat
Carolina 25. The Carolina 25 is a classic North Carolina sport fishing boat design in a trailer-able center console layout. This design features the famous Carolina flare, broken shear and tumblehome that is sure to turn heads. This boat is built using the cold molded method and best suited for those with boat building or woodworking experience.
Cold-Molded Boats
Posts: 1,178. Cold molding is a master craftsman's artform. It's tough, light and strong (as in the British Mosquito of WWII) but requires exacting care to prevent small voids in the layup. I recall a cold-molded sailboat was built to be dropped from an airplane to let downed pilots sail away to safety. That's tough.
Time Lapse of Cold-Molded Wooden Boat Building
The first half of building a cold-molded wooden power yacht here at French & Webb in Belfast, Maine.
Cold Moulded Boats Illustrated Guide
Or would that still be considered a cold molded boat? 05-11-2016, 19:53 #12: Jim Cate. Moderator . Join Date: May 2008. Location: cruising SW Pacific. Boat: Jon Sayer 1-off 46 ft fract rig sloop strip plank in W Red Cedar. Posts: 21,280 Re: Cold Moulded Boats Illustrated Guide.
Building with the cold-moulded method
Building with the cold-moulded method. After an unfortunate motorbike accident, Harry Evans was forced to put his boating career on hold. However, an opportunity to train as a boatbuilder at the Boat Building Academy in Lyme Regis has given him a fresh start. Here, Harry tells us about his work at the college to build a Clinker sailing boat ...
Van Dam Custom Wooden Boats & Yachts
From the cold moulded structure to the electrical and mechanical integrations, we perfect the build process on each custom wooden boat. ... Van Dam Custom Boats are built for generational enjoyment and constructed to stand the test of time. 3D CAD In the design phase we shift from 2D drawings to 3D virtual models, using state-of-the-art 3D ...
The Gougeon Brothers Boats
Built in 1976, Hot Flash was a cold-molded, fast, half-ton racing monohull designed by Gary Mull. The Usnis brothers, who sailed out of Detroit's Bayview Yacht Club, commissioned the Gougeons to construct her with wood and WEST SYSTEM Epoxy. The boat was later rechristened Boomerang.
Overview of Cold Mold Construction
Forming a monocoque structure (key point) It is called cold-mold because the binder (glue / resin) is designed to fully cure at room temperature. From Wikipedia: Monocoque, from Greek for single (mono) and French for shell (coque), is a construction technique that supports structural load by using an object's external skin as opposed to using ...
Six River Marine
The cold-molded wooden hull is lighter with a more quiet and comfortable ride than its typical fiberglass counterpart. It requires a smaller engine for the same performance. ... a cold-molded boat requires no more annual maintenance than an aluminum or fiberglass boat. The rigid one-piece hull structure provides an excellent base for any paint ...
Cold-Molded Boats good or bad?
A cold molded boat is a boat with a laminated wood or fiberglass hull. The wood is cut into thin strips about 1/8" thick. these are then bent over frames on a diagonal to get the hull shape. Subsequent layers are added with epoxy resin, on the diagonal running the opposite way so they cross. Essentially the hull becomes a single thick piece of ...
Is a Cold Molded hull Viable? Insurable? Safe?
It is safe to say that bare cold molded wood was exposed outdoors in salt air for no less than 5 years and the only loss to rot was an inch at the transom -to be expected because it was stored upright without a cover. Other than filling some gaps (less than 1mm) the hull is terrific in clear epoxy -like jewelry.
The New Cold-Molded Boatbuilding
Description. It's generally agreed that cold-molded construction is the best method for the amateur or independant professional interested in building a full-size cruising sail or power boat. A truly appropriate technology, cold molding combines the beauty of wood with the low-maintenance characteristics exceeding those of fiberglass.
The New Cold-Molded Boatbuilding
The New Cold-Molded Boatbuilding. 320 pages, lots of black & white photos and illustrations, soft cover. It's generally agreed that cold-molded construction is the best method for the amateur or low-profile professional interested in building a full-size cruising boat. A truly appropriate technology, cold molding combines the beauty of wood ...
IMAGES
VIDEO
COMMENTS
Cold Molded Construction. Cold molded hulls have been built since the technique was used for World War II planes—often using casein or urea-based glues. Today, one would use epoxy almost exclusively, benefiting from its superior bonding, gap-filling, strength and water resistance. ... The pre-cut veneers (2-6 mm thick depending on boat size ...
Brooklin Boat Yard has been building cold-molded boats since 1990. That first boat, a 55-footer for then-yard President Steve White, is still racing and looking good, Larkin says. It's evidence that cold-molded boats can be incredibly durable. "We've built 112 boats total," Larkin says.
Keel raised: 0.8-1.0m (2ft 8in-3ft 3in) Displacement: 1.5 tonnes. Ballast: 600kg (1,322lb) Engine: Torqeedo Cruise 2.0FP. Price: €120,000 (ex. VAT) The LA 28 is a beautiful, cold-moulded wooden ...
French & Webb and Belmont Boatworks build the hull of the Paine 15 sailboat, designed by Chuck Paine. Video and narration by Chuck Paine.
With a low-maintenance, cold-molded hull that offers the unmatched, comfortable motion and ambiance of a wooden boat with the 10-knot-plus speeds of a modern performance yacht, you and your family will form a bond with the LM46 that will last generations. ... Using the cold-molded building process results in a hull that delivers a quiet ride ...
Boat Building in "Cold Moulded". Moulded Ply or Veneer. This method of construction can be used to build several of our designs, and plans are available based on this technique. From full size patterns supplied with the plans , station frames are marked and cut out of scrap timber and plywood. Stringer positions are marked and notched.
Parker Marine Boat Plans. PARKER MARINE ENTERPRISES sells Construction Manuals, Catalogues, Study Plans and Full Stock Plans. We do custom design work for construction in cold-molded wood, plywood, traditional wood, fiberglass, aluminum, ferrocement and steel. We do on-site or remote consultant work for new construction and major restorations.
Cold-molded boats start off upside down and are flipped during the build process. Even as many custom builders embrace Computer Aided Design (CAD), Blackwell prefers to adhere to traditional boatbuilding skills. This builder starts by hand-lofting each vessel, which, in brief, means he makes to-scale drawings of each.
This boat, like our other V-bottom hulls, was built using a stringer/frame system. In this system, transverse frames are erected, in this case on 20" centers. Over the frames go longitudinal stringers. The cold-molded planking goes over the stringers. In the photo, the frames are set up and faired, ready for the stringers.
Vicem, which recently consolidated all of its operation in Antalya, is practically synonymous with cold-molded construction. It has been utilizing cold-molded construction techniques since its first yacht—a 62-foot (19-meter) sailing ship, launched 20 years ago. The company recently celebrated its 20th anniversary by introducing the Vicem 100.
Carolina 25. The Carolina 25 is a classic North Carolina sport fishing boat design in a trailer-able center console layout. This design features the famous Carolina flare, broken shear and tumblehome that is sure to turn heads. This boat is built using the cold molded method and best suited for those with boat building or woodworking experience.
Posts: 1,178. Cold molding is a master craftsman's artform. It's tough, light and strong (as in the British Mosquito of WWII) but requires exacting care to prevent small voids in the layup. I recall a cold-molded sailboat was built to be dropped from an airplane to let downed pilots sail away to safety. That's tough.
The first half of building a cold-molded wooden power yacht here at French & Webb in Belfast, Maine.
Or would that still be considered a cold molded boat? 05-11-2016, 19:53 #12: Jim Cate. Moderator . Join Date: May 2008. Location: cruising SW Pacific. Boat: Jon Sayer 1-off 46 ft fract rig sloop strip plank in W Red Cedar. Posts: 21,280 Re: Cold Moulded Boats Illustrated Guide.
Building with the cold-moulded method. After an unfortunate motorbike accident, Harry Evans was forced to put his boating career on hold. However, an opportunity to train as a boatbuilder at the Boat Building Academy in Lyme Regis has given him a fresh start. Here, Harry tells us about his work at the college to build a Clinker sailing boat ...
From the cold moulded structure to the electrical and mechanical integrations, we perfect the build process on each custom wooden boat. ... Van Dam Custom Boats are built for generational enjoyment and constructed to stand the test of time. 3D CAD In the design phase we shift from 2D drawings to 3D virtual models, using state-of-the-art 3D ...
Built in 1976, Hot Flash was a cold-molded, fast, half-ton racing monohull designed by Gary Mull. The Usnis brothers, who sailed out of Detroit's Bayview Yacht Club, commissioned the Gougeons to construct her with wood and WEST SYSTEM Epoxy. The boat was later rechristened Boomerang.
Forming a monocoque structure (key point) It is called cold-mold because the binder (glue / resin) is designed to fully cure at room temperature. From Wikipedia: Monocoque, from Greek for single (mono) and French for shell (coque), is a construction technique that supports structural load by using an object's external skin as opposed to using ...
The cold-molded wooden hull is lighter with a more quiet and comfortable ride than its typical fiberglass counterpart. It requires a smaller engine for the same performance. ... a cold-molded boat requires no more annual maintenance than an aluminum or fiberglass boat. The rigid one-piece hull structure provides an excellent base for any paint ...
A cold molded boat is a boat with a laminated wood or fiberglass hull. The wood is cut into thin strips about 1/8" thick. these are then bent over frames on a diagonal to get the hull shape. Subsequent layers are added with epoxy resin, on the diagonal running the opposite way so they cross. Essentially the hull becomes a single thick piece of ...
It is safe to say that bare cold molded wood was exposed outdoors in salt air for no less than 5 years and the only loss to rot was an inch at the transom -to be expected because it was stored upright without a cover. Other than filling some gaps (less than 1mm) the hull is terrific in clear epoxy -like jewelry.
Description. It's generally agreed that cold-molded construction is the best method for the amateur or independant professional interested in building a full-size cruising sail or power boat. A truly appropriate technology, cold molding combines the beauty of wood with the low-maintenance characteristics exceeding those of fiberglass.
The New Cold-Molded Boatbuilding. 320 pages, lots of black & white photos and illustrations, soft cover. It's generally agreed that cold-molded construction is the best method for the amateur or low-profile professional interested in building a full-size cruising boat. A truly appropriate technology, cold molding combines the beauty of wood ...