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Building a Foam Core Boat

by Ron Palmer

112 pages; quality trade paperback (softcover); catalogue #00-0120; ISBN 1-55212-455-X; US$16.50, C$20.00, EUR13.00, £9.10

This is not a technical book. There are many of these publications on the market, some written by experts in the field, others written by those who have been diligent in their research, and presented a book covering all aspects of boat building. rather, this book has been based on the author's experience in building a boat with the foam core method. And as such is offered to the reading public for their consideration. Secondly, the book could also be of benefit to other prospective amateur boat builders, giving them the necessary boost to their confidence, and to their commitment.

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about the book      about the author      sample excerpt      catalogue info

About the Book This book comprises twelve chapters. Each one dealing progressively with each stage of constructing a boat using the foam core method, from building the jig the boat will be built on, to the finishing of the interior. Not only is the narrative clear and concise, without recourse to digression, it has the amateur builder in mind. By following the procedures laid down it will be possible for anyone with even the least talent on this subject to construct a boat from start to finish. For those who only wish to know how a boat is constructed, then this book is a must.

About the Author The author was born in 1933 in Bridlington, a fishing and resort town on the east coast of Yorkshire. At an early age he became interested in a career at sea, taking every opportunity to go out with the local fishermen. 1948 found him enrolled at the Boulevard High School for Nautical Training at Kingston upon Hull. On completing his schooling in 1950, Palmer went to sea as apprentice deck officer, working up through each stage of navigating officer to retire as captain of super tankers in 1985. He now lives on Pender Island, B.C. Canada.

Sample Excerpt

This is not a technical book. There are many of these publications on the market, some written by experts in their field, others written by those who have been diligent in their research, and presented a book covering all aspects of boat building. Rather, this book has been based on the author's experience in building a boat with the foam core method. And as such offered to the reading public for their consideration. Apart from this there is no presumption of expertise.

The reasons for writing this book are two fold. Firstly, after spending every waking hour of every day, during the time frame of building this boat, thinking of precious little else but the planning and the hands on application of each stage while the construction was in progress, I became totally committed to the project, until it became an obsession. Which, when the boat was launched and completed left me with a mental void, and at a complete loss as how to occupy my time. Just like many amateur boat builders, the desire to build another boat was uppermost in my mind. But that was impractical, and financially impossible. After all what would one do with two boats, or more, if the obsession continued. Therefore, what better way to exorcise this particular demon than to commit it to paper. It certainly would be cheaper. And the boat would be built again if only in my mind. Secondly, the book could also be of benefit to other prospective amateur boat builders. Giving them the necessary boost to their confidence, and to their commitment.

My first boat was a Tanzer, 28ft. A very nice boat it was too. But not roomy enough for my wife. This is not surprising, I suppose, as like most women, they do like their creature comforts, away from, as well as in the home. Bigger of course being roomier, and by definition more comfortable.

So the search started, initially, for a suitable hull which could be brought over to the island on which we live and be fitted out here. Trade magazines, newspaper classified, etc, were perused with no satisfaction. During this search an advertisement for a catalogue of a hundred boat hulls was noted. This was duly sent for, and perused. There was absolutely no doubt in either my mind, nor my wife's, that the Van de Stadt, Norman was the boat we were seeking. The interior was roomy, light and airy. It had a large galley, and a good sized bathroom with shower. A choice of two or three cabins. And most importantly a saloon that was raised sufficiently to give an all round view. One could sit comfortably here when at anchor, supping a beer, and watch the world go by.

In effect it was a boat that one did not have to go down into a dark hole, to be cut of from the outside world. And, although it had the look of a motor sailer it wasn't. In due course it proved to be an excellent boat under sail. Giving a hull speed of seven knots. There was absolutely no doubt this was "IT".

Initially the Study Plans were obtained, which in retrospect were found to be unnecessary as these plans were intended for securing estimates from the different boatbuilding trades, and as it was eventually decided that the boat would be built by myself these plans became superfluous. But then ignorance is bliss. During the period between receiving the study plans up to obtaining the full drawings much agonising over procedure ensued. Should a boat builder be commissioned? Would a steel hull, or aluminum, or possibly fibreglass be the best way to go? The idea of having the boat built was rejected, for during the course of this agonising I had obtained Ken Hankinson's book, Fibreglass Boatbuilding for Amateurs which tipped the scales in favour of a fibreglass hull. For I felt that if I was to build the boat myself then, surely, fibreglass skills would be easier to learn than the welding of steel or aluminum. Other considerations that came to mind were that steel will rust making for extra up keep, and with aluminum that bogey man electrolysis came to mind. Or should I say that a copper coin inadvertently drop in the bilge would in time eat through the hull. Advocates of either of these two materials would probably poo-poo these concerns. But then each to their own.

Having reached this decision, another problem cropped up. The design called for steel or aluminum, but not fibreglass. This problem was put to the designers who were advised of my wish to build with a fibreglass foam core. Their response was very positive, and they kindly supplied a combination of two different plans to alleviate this problem, and also a laminating schedule for this particular size of boat.

The examples and explanation of methods in this book are based on the actual building of the Van de Stadt, Norman. A 40ft, sloop rigged sailboat. Built by the author without any previous knowledge or experience of boat building. But with an insatiable appetite to bite of more than can be chewed, and finding that it wasn't such a large bite after all. In fact it turned out to be more of a tasty morsel, giving an unbelievable satisfaction, and pride, in a most wonderful experience.

The principals of construction involved can, with a little insight, be applied to any design of boat, using the fibreglass, foam core method. And the prospective builder should not be daunted at what might at first glance seem to be an impossible task.

This book is designed to help those of you who have always wanted to build a boat but have lacked the confidence to attempt what you may fear will be a monumental undertaking. Believe me it isn't. If you know your way around tools, preferably power, and have a little practical no-how. Then you can do it.

I have attempted to use a straight forward approach with no dross or waffling for the reader to wade through. Just a narrative on how to build a boat from scratch to the finished product. This, no doubt, will account for it being such a slim volume.

Accompanying the drawings were full scale Mylar frame outlines, which makes lofting unnecessary, a definite must for those who lack this particular expertise. When choosing a design for your project this should be uppermost in your mind. It will save a great deal of time, and a great deal of space that one needs to do the lofting.

It only remains for me to wish you good luck on your enterprise, and hope you find the enjoyment and satisfaction of a truly worthwhile undertaking.

dining area

Catalogue Information