When we built the prototype we made plywood templates of all the hull panels to make it quicker this time. The frame is still in good shape as well.
The foam was cut to length and joined with polyester resin and aerosil, covered with glass, resin and peel ply. We cover the glass with peel ply to fill the weave in the cloth and make the boat easier to finish. We found it also makes the glass adhere to the shape when glassing around corners.
The panels for the mainhull shell and both float shells are finished and cut out using a jig saw with a special blade. We use Makita jig saws and either 42 (flat top) or B21 (shovel top).
One of the beams was also built during this time. When working I like to have as many jobs going as possible to ensure the most efficient use of time and resources.
Total time so far 43 hours.
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