Friday, August 14, 2009

Part 1 - Hull making

Let's begin. The hardest part of making a sailboat is probably the Hull. U might have a downloaded plan which indicated parts which are usually to be made from wood. Other than cutting, U have to sand, glue, seal, sand, lacquer and paint. Quite a lot of work especially for one just starting out !! Most newcomers would get turned off from here. Is there a better way to make hulls ? simple and fast way ? One U can make within 1-2 hrs not weeks ? I would like to share with U my method. There is a readily available material that allows U to do so -- 2mm EVA foam sheets !! EVA or Ethylene Vinyl Acetate is a chemically safe, flexible polymer that is itself waterproofing and does not get wet. Used normally for children's handicraft work in schools, the foam sheet comes in both B3 and A4 sizes and in various nice colours ( red, green, yellow, brown, white, black, pink.....) and U get buy them quite cheaply from handicraft stores or in schools in Singapore. Also check http://www.sesco.com.sg/ for the foam material too.
There are a number of ways to make a Hull using a 2mm A4 size EVA foam sheet, One basic way of folding EVA to form a conventional looking hull is illustrated in the pics shown below. Secure each fold temporarily using a clip.

Once U are satisfied with your folded hull ( it should be symmetrical ), it's time to apply glue to the folded areas. The glue I am using is the UHU Twist & Glue and it is very effective for all kinds of foam materials.

U may need to cut and trim the hull further after glueing to get a nicer shape. The blue hull which I folded for my blue footy is shown in the pics below. Notice that I have added a foam deck. U might want to use the 5mm (3mm?) foam sheets obtainable from ArtFriend for the deck. I have used Depron which is imported from USA. Also a triangular foam reinforcement at the base is added. Overall, depending on how U fold your EVA sheet, U should be able to get a hull shape like the one shown. So U got yourself a quick, simple and colourful hull without the need for further sanding, sealing and painting and it's already waterproof !! All can be done within 2-3 hours !!

I shall end the posting with a link to a video of my Blue Footy which I maiden sailed at Bedok Reservior not too long ago : http://www.youtube.com/watch?v=xY_ikfTqrWI Hope U enjoy watching it. Cheers !!