Instructables

Making a Plywood Kayak

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Step 6: Fiberglassing Details

Get the epoxy distributed just about to the end. Then smooth out one side of the glass all the way to the stem, allowing a large wrinkle or fold to accumulate on the other side.
Use scissors to cut down along the stem fillet, snipping all the way to the bottom.
Pull back the loose side of the cloth and tuck the smooth side back into the fillet, removing any wrinkles that may have appeared from your cutting. Then tuck the loose side in to over lap the existing glass. If the overlap extends more than about 2 inches you can trim off the excess.
Spread epoxy onto the cloth using your brush as needed to apply epoxy into the over lapping cloth.
If you end up with a gap in the cloth for some reason, just cut a patch from any scraps you cut off earlier.
Now for those bridges of cloth at the chine. These appeared as you squeegeed epoxy up the sides. As you did this you pulled a little fabric up with the resin. As a result there is not enough fabric in the boat to fill into the fillet.
The solution to this is introduce a small amount of cloth back down into the seam by sliding it down from the top.
With a somewhat dry brush place just above the fillet and pointed down, lightly press the fabric down towards the fillet. It should slide fairly easily, but sometimes it gets caught up on the rough top edge of the plywood. You may need to lift the cloth at the top away from the edge a bit so it doesn’t snag.
Work gently from one end of the bridged fabric to the other, sliding the fiberglass down into the bubbled area. You may not need to add any more resin, but as you do this look for areas that are slightly gray or look starved for resin. If there is a shiny spot near by, use your squeegee to spread the excess resin in the shiny spot to the dull grey spot. If there is not source of resin already in the area, blot a brush full of resin on the spot then squeegee it around.
Inspect the hull for bridges and dry spots before going on to the deck. You have now competed the hardest fiberglassing work of the whole project. Everything else will be easier.
 
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