Building a Foam Sandwich Sabre Sailing Dinghy at Home

Рет қаралды 32,953

Matt Westland

Күн бұрын

Matt talks about the process of building a Sabre sailing dinghy at home using foam and glass.

Пікірлер: 61

@felixcat9318 Жыл бұрын

Thank you for compiling this very interesting and informative video. Your boat looks absolutely gorgeous, and I can only imagine how proud you must be. I'm thinking of a 9 foot folding boat so the longest length of foam will only be 4.5 foot. I originally thought of using marine plywood, but foam, fibreglass cloth and resin are increasingly attractive for the project. It won't be a sailer, just a kayak paddle or outboard motor for propulsion.

@mattwestland8809 Жыл бұрын

Hi Felix Cat. When you say folding boat I assume you mean a boat that bolts together in the middle.... or you might be meaning something else.There is a dinghy made from plastic panels with flexible seams which folds up into a flat pack. I reckon 6mm foam would be enough for a 9 foot boat. Cheers matt.

@Antipodean33 Жыл бұрын

I use an Aussie made epoxy called Bote Cote, water based so no rashes etc and also no amine blush. I built a 17 foot sea kayak 15 years ago that is still in excellent shape and I'm using it to build a fishing boat at the moment. It's a 2 to 1 as well, it's very good and not that expensive

@antiussentiment Жыл бұрын

This is a great product that I use to use. And Bruce McConkey (if I recall?), the owner. Is super helpful if you call with a question.

@llamabob2 Жыл бұрын

Thank you for sharing your build video!

@NA-su3jk Ай бұрын

Thank you, well done! I will rewatch in case I missed it.. but how much does this one weigh, and how does that compare to its class standard units built using old methods please?

@mattwestland8809 Ай бұрын

If you build to the rules in ply you can just get it to minimum weight 41kg using light weight timber and minimal scantlings. It’s much easier to build to weight using foam and glass. Mine was nearly 1 kg under.

@SauronsEye 3 ай бұрын

I remember the time a bloke described an oscillating saw to me for the first time. I really thought he was having me on about how it can cut wood and ceramics, anything almost but it won't cut you. I was in disbelief that such a tool could exist. I eventually agreed with him that it could cut almost anything but I wouldn't believe that it wouldn't also cut skin. I'd only known saws requiring large strokes to cut...not itty bitty tiny strokes being able to do the same thing. He got a hack saw blade and showed that just with tiny up and down movements it could cut through wood. Slowly of course. He then put the blade against my skin and moved the blade up and down as much as he did on the wood and I wasn't cut because my skin moved. It was then I believed such a tool could exist. I was amazed at the ingenuity behind it but I was also feeling dumb that I hadn't at least heard about the concept for this tool, even before it became a prototype. I prided myself on learning about new discoveries and then watching them be developed into practical uses but here was a thing I had never heard of before...how could that happen. To this day, I have no idea but who ever thought to make am oscillating saw blade tool was a genius at keeping a secret.

@mattwestland8809 3 ай бұрын

@@SauronsEye yep agree it’s a great tool. I’m still finding ways to use it for all sorts of jobs.

@JenkinsBoatWorks Жыл бұрын

what a wonderful video. thank you!

@Peter_Herrman Жыл бұрын

Great video, thanks! What was the first layer of fiberglass you put on the foam before you stitched it all together? Curious what weight and type? CSM? WR? Uni? 16oz? I'm assuming it was pretty thin so you could still bend the panels. And was that glassed side placed on the inside or outside of the boat when you put it together - I can't tell from the pics. I thought I'd heard it should go on the inside, but it kind of looks like maybe you did it on the outside. Really helpful video - thanks again!

@mattwestland8809 Жыл бұрын

Hi Peter 200 gram or 6oz plain weave. Put glass on inside first unless the panels have to bend a lot ,like at the bow. Leave glass off in those areas until put together and outside is glassed. On outside I used a 295 gram twill which layer down well. cSM is no good with epoxy. I used Uni in areas inside that needed strength one way.

@mattwestland8809 7 ай бұрын

Hi Peter one layer of 6oz on inside of panels. Very front panels should have no glass till they are pulled into shape.

@TheStoryLeader 3 ай бұрын

Fabulous video Matt. Did you vacuum bag any of the panels or structure?

@mattwestland8809 3 ай бұрын

No vacumn bagging. Just peel ply for some areas.

@michaelkrochmann7239 7 ай бұрын

Brilliant instructions, thank you! Has anyone build one like that in Melbourne?

@mattwestland8809 7 ай бұрын

Hi Michael as far as I know none as yet. Our Tas Association is making plans to build a male jig over which a hull can be built. We have 4 foam boats built by amateurs in Tassie. They have all turned out well. Cheers.

@neilboardman6640 Жыл бұрын

great vid. im very interested in the cost and availability of the foam. where in AU do you get gurit corecell m80 8mm and whats it cost ?

@mattwestland8809 Жыл бұрын

Hi Neil should be available in all big cities. ……marine shops or fibreglass supplier. Or look on Google for Gurit and their distributor near you. Best luck.

@johnravensbergen3324 5 ай бұрын

Thanks for sharing!! Great video

@markthomasson5077 Ай бұрын

Did you use Peelply? Could you not have used the lay out table, with a smooth surface, to mould face down, so get a good finish

@mattwestland8809 Ай бұрын

@@markthomasson5077 I used peel ply on smaller layup jobs. I didn’t have enough work time on the bigger lay ups as I was working solo. Moulding face down you ideally need to vacuum foam down. I didn’t have access to such gear. Low tech works fine. If doing again I’d use epoxy.

@markthomasson5077 Ай бұрын

@@mattwestland8809 …know what you mean. I guess the trick is to prepare the Peelply and tape down on one edge, then fold back. It then only takes a second to fold back over. Yes you would need some pressure to do face down. The proper ones are very expensive, though I have seen KZbin of folk using shop vacuum sweeper. Some experiments would be wise. There is so much work involved in getting a good surface, hence the desire to try face down. And you could start with a gel coat

@StuartD-g4i 3 ай бұрын

I watch all these videos but nobody says what type of foam it is The technical buying name Where it's available

@mattwestland8809 3 ай бұрын

Gurit M 80 . The 80 is 80kg/cubic metre. Available in Australia. Used worldwide. Other density’s available.

@michaelkrochmann7239 Жыл бұрын

Thank you!!

@henrydelport6513 7 ай бұрын

Matt. Maybe I missed it but wat was the total man hours put in?

@mattwestland8809 7 ай бұрын

Not sure. I fiddle a lot so even if I offered a number it would be different to what most people would take. Probably about 20 to 30% more than a ply build due to more glassing ,filling and sanding.

@antiussentiment Жыл бұрын

Last year I built a 2.4 meter tender for our little yacht using 3mm MDF as a core material. The little boat is light and very strong (has survived a drop off the carry racks on my ute with no real damage). We have a very active Sabre fleet at our club and I've often wondered about building and MDF/epoxy Sabre. I've done a playlist of the building process on my channel.

@mattwestland8809 Жыл бұрын

Hi Noisy Andrew , I'd be very sceptical of the longevity of a Sabre made with MDF core. It's great you have built a tender that works. At the risk of sounding critical the only advantage I see for MDF is it's cheap and smooth. Sooner or later when the boat gets a ding or scratch through the glass and you miss it, it will blow. Just leave some MDF in the rain to see what will happen. The stiffness of glass skins over core is a combination of glass weight and thickness of core. 8mm foam makes for a seriously stiff and light hull which is what you need for a fast boat. Yep the foam costs more but is insignificant in the overall cost of a racing dinghy. Ill have a look at your channel. Cheers matt.

@antiussentiment Жыл бұрын

@@mattwestland8809 oh.. and what I didn't mention was that the build up to priming and top coat was about $650. Using MDF means it's so strong that you need a lot less glass and resin than you otherwise would..

@Antipodean33 Жыл бұрын

MDF??? I'd never build a boat using that, thats crazy

@antiussentiment Жыл бұрын

@@Antipodean33 go look at the videos. I actually got invited to speak/present at the Armature Boat Builders of Australia. They all seem pretty impressed, especially with the strength and the cost. The video series has a bunch of testing etc for strength and water absorption of laminated MDF if you're interested?

@eric99vigne 5 ай бұрын

At the bottom the hollow it is the Self bailer right?

@mattwestland8809 5 ай бұрын

Yep at lowest point which is at aft end of centre case. I put in a second one aft but it’s not needed.

@mattwestland8809 5 ай бұрын

Yep

@truongluu9437 Жыл бұрын

I wonder how heavy it is?

@mattwestland8809 Жыл бұрын

It’s lighter and stiffer than a build in 4mm gaboon ply.

@nilosantos4862 Жыл бұрын

The totAl cost between play wood stick and glue and PVC foan cover with 400 grams Fiberglass the last case will be higher. But in terms of weight either?

@mattwestland8809 Жыл бұрын

Hi Nilo, with 6 or 8 mm foam and 400gram glass either side it will be stiffer and lighter and stronger than 4mm ply.

@robertcain3426 Жыл бұрын

@@mattwestland8809I think the foam core laminate will be more rigid but doubt its stronger than ply. I've seen comparison figures which specify either 34oz/20mm foam core/34oz laminate or 9mm marine ply. The marine ply is not as stiff and needs more stringer support than foam. In that spec sheet, the weights of ply verses foam are equivalent. Also, in regard to weight, I was surprised how light your laminate was with only 200g cloth each side. I suspect it would be below recommended thickness. Having said that, the conclusion for me is that the core laminate is more rigid, though perhaps more expensive. Thanks for the video. Cheers

@malmotumotu5218 2 ай бұрын

Hi where do you get your core foam from?

@mattwestland8809 2 ай бұрын

@@malmotumotu5218 I’m in Tasmania. Purchase from Fibreglass Shop but there are other suppliers. Depends on your location.

@malmotumotu5218 2 ай бұрын

@@mattwestland8809 thank so much for your reply! Thank you sharing your knowledge and experiences with us🙏🏽

@markthomasson5077 Ай бұрын

What is the work time with vinyl ester

@mattwestland8809 Ай бұрын

@@markthomasson5077 work time depends on ambient temp as well as how much hardener is used. 20 mins is about right.

@markthomasson5077 Ай бұрын

@@mattwestland8809 . Thanks, so similar to polyester. You have to be quick and accurate. Danger of messing up quite high. So the extra cost for epoxy may be worth it, and you should get away with less as you have more time to work it in. I have been meaning to so far, so go for the cheapest…which may be false savings, epoxy and now I discovered Peelply I am a convert.

@DangTue-bo4bw 6 ай бұрын

How heavy is it? if I can ask.

@mattwestland8809 6 ай бұрын

Hull is 40 kg. Just 1kg under weight n

@DangTue-bo4bw 6 ай бұрын

@@mattwestland8809 Thank you for your information.

@PEOdysseus Жыл бұрын

HOW DO i SEE YOUR DRAWING PLANS OF HOW YOU MADE IT?

@mattwestland8809 Жыл бұрын

Hi PE there are no drawings as such. There are building notes on the Sabre website. The template shapes are available from your state association or a CAD file when you apply for a building number.

@StuartD-g4i 3 ай бұрын

Sadly the country i live in now, Colombia Sth America this stuff is not available, I guess good ol fashion ply will do the trick. Cheers..

@mattwestland8809 3 ай бұрын

Yep 4mm ply works perfectly. Add a thin layer of glass to outside bottom for added stiffness and wear resistance.

@dc-wp8oc Жыл бұрын

Are we just creating more landfill material? How can fiberglass or any composite material construction ever be recycled? Isn't the world overflowing with products that do not lend themselves to the recycle stream?

@murrayobrien9192 Жыл бұрын

FFS mate I don't think building a few Sabre racing dinghies is going to do a whole lot of damage. Maybe you ought to consider the waste from wind turbines. Unrecyclable and defunct after 15 years.