cold molded sailboat

Cold Molded Construction

Cold molded hulls have been built since the technique was used for World War II planes—often using casein or urea-based glues. Today, one would use epoxy almost exclusively, benefiting from its superior bonding, gap-filling, strength and water resistance.

The temporary framework (or jig) will commonly allow for a permanent gunwale to be fitted as well as a keelson, as the diagonal veneers will be permanently attached to these.

Wood for the veneer strips is very critical. It must be cut flat with even thickness, be well seasoned and resistant to cracking. Western red cedar and mahogany are two good choices. Some builders even use thin, high quality plywood.

The pre-cut veneers (2–6 mm thick depending on boat size, bilge radius and stringer spacing) will typically be laid up about 35-45 degrees from the vertical and stapled to the stringers where they cross and also near both edges.

Veneer width will depend on the curvature of the hull, with more curvature requiring narrower strips. Knowing what radius various woods can bend will help decide the strip size and thickness for a particular shape.

This table is from a fine book entitled 'The Gougeon Brothers on Boat Construction' - with their kind permission.

If the staples are arranged in a row and a strip of tough strapping material laid under them, they will be much easier to remove without damaging the wood.

(This sketch also comes from the excellent book 'The Gougeon Brothers on Boat Construction' and shown here with their kind permission)

After the 2nd layer, modern builders are now often enclosing the whole surface with plastic and vacuum-bagging the bond to improve pressure between the surfaces while curing. But this requires that the working surface of the mold be made air-tight and that is impossible with an open frame+stringer arrangement. One interesting method (see URL below for Nexus Marine) is to seal the first layer airtight and then vacuum bag to that. Either way, if it can be done, vacuum-bagging is surprisingly effective and not that difficult either as long as certain precautions are taken (see separate article on this).

Some larger designs call for a 3rd veneer layer—perhaps even laid up fore and aft for appearance. In such a case, this could well be the hardest layer to fit, especially if the hull has a sharp radius in its section. Narrower strips will help in this case but that means more joints to fit. (I'd personally suggest to avoid a lengthwise veneer and plan on painting the exterior.) Once cured, the exterior is typically sanded and at least partly faired before removal. Cold-molding is good when you have a capable partner to work with as you can each work on strips, starting amidships.

Click here for clear photos of the process: www.sixrivermarine.com/Cold%20molding%20QA.htm www.nexusmarine.com/odysy_const.html (with vacuum bagging) www.bruceroberts.com.au/gallery/index.htm (see Roberts 24 and Roberts 25 wood)

Advantages are: If well executed, this system produces a very tough, long-lasting hull that is stiff and resistant to damage and rot. It requires only the minimum of internal stiffening. Still a useful option where labor costs are low or just not counted.

Disadvantages: The system is pretty labor intensive and solid veneers of moisture-resistant wood are also becoming expensive and difficult to obtain in some parts of the world. The system also requires a good, solid mould prior to construction, which has no further use after the hull is lifted off. The surface, both inside and outside, also requires a considerable amount of sanding and the outside will need additional fairing to get a professional finish. As this is more work than other competing systems, this system is now used less and less, except where labor costs are low or discounted. The Constant Camber system was first developed to try and overcome this high labor issue—see separate article.

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HIGHER QUALITY, LOWER COST COLD MOLDED CONSTRUCTION

Todd French of French & Webb Boatbuilders in Belfast, Maine has been thinking about this for years. Dan Miller, of Belfast Boatworks, enthusiastically agreed to provide his workspace and skilled workers. What if there were a way of laying up a WEST-system yacht hull with something approaching the efficiency of laying up a fiberglass hull? They knew that it would require;

• An expensive, completely fair and “closed”, male mold. In fiberglass layup the same tradeoff is made in the industry― you acquire a very high cost but perfectly smooth mold, so that the individual parts that come out of the mold can be constructed quickly… you spend more money upfront in order to spend less money later and attract a bigger market. Alternatively, in the case of cold molded wood construction, this requires a male, not female, mold, and you end up with a hull that is perfectly finished on the inside, but must be faired and painted on the outside. Meaning such hulls will never be built as cheaply as can a fiberglass hull. But on a boat where the inside of the hull is always visible, like the LEVANT 15 daysailer, the tradeoff is that it is easier to fair and paint a convex surface (the outside) than a concave surface.
• A team of highly trained workers. This is not necessary in fiberglass construction- there are no time constraints (you can apply as few or as many layers of cloth as you like in a given day). Todd’s objective was to laminate an entire half of a yacht’s hull in one intense session. He reckoned this could be done with four active workers, plus one in the background to fix problems when they emerged.
• A proper vaccuum-bag pump, process materials, and workers who were trained how to use it under time pressure.
• And a yacht design that would have sufficient appeal to justify the large initial expenditure for a perfectly fair, closed, vacuum-baggable mold. You wouldn’t want to invest in this sort of mold if you were building only one or two boats.

Todd decided to try this approach on his new  LEVANT 15 daysailer.  It had the advantage of being small enough to potentially laminate four layers of wood veneers in one session. The constraint here is the time available before WEST-system epoxy cures. By keeping the workspace cold (below 50 degrees) and using slow hardener, this meant four hours of working time before the epoxy begins to cure, when the heat is turned up to finalize the cure. But is it possible to apply 240 veneers in four 60-veneer layers, within such a short timeframe? Todd teamed up with his boatbuilder friends at Belmont Boatworks, just up the road, in order to have a large enough team to attempt it. The video below should give you a good idea of the process.

Todd wisely began by building a small test panel, just to make sure there were no unforeseen problems. Using conventional techniques epoxy primer is the last thing to go on, and fiberglass cloth is pressed onto a surface from the outside rather than pulled into the primer by a vacuum. The test panel proved that there were no problems using the vacuum to press the “skin” layers into each other rather than using a serrated roller and paint sprayer as is the usual case.

The mold was waxed, and a layer of epoxy finish primer applied to the mold. This would become the visible layer on the inside of the hull once the finished part was removed. No time pressure here― it could have been done days in advance. A layer of 10-ounce fiberglass cloth was then laminated on in fast-cured epoxy resin. Again, no time constraints, and this was allowed to cure.

Then began many hours of pre-fitting the lightweight cedar veneers. Beginning with the inside layer (inside the boat once it is finished), the 1/10″ thick cedar veneers were stapled into place, and marked and numbered and carefully stacked so that they could later be selected and rapidly re-stapled into place on layup day. Just one single veneer out of place in the stack would precipitate disaster, as you can imagine.

The layup day was choreographed in advance. Four stacks of veneers, four workers who could have at it for potentially four hours without a bathroom break, and somebody gutsy enough to say, “start.” The veneers were put into place and sporadically fastened with plastic staples― easily sanded flush when necessary. After only 2 1/2 hours the four layers were in place, and the vacuum bag going on. Somebody must have been heaving a sigh of relief, and wondering just how much larger a boat could be built with this method?

Is this the future of boatbuilding? Fiberglass has not run its course, surely. But the market for pleasure boats has evolved. Poorly designed sailboats, sold on the basis of their low price, have no future but to fail, You can buy old fiberglass sailboats for nothing on craigslist. You make the decision to own a sailboat for the joy of sailing her. But you are not a fool and you thing “green” and you hope that the effort and resources that go into her will endure until your grandchildren grow old.  If so, you will choose a  LEVANT 15 built by Todd French, and you will have chosen wisely.

This article is about entrepreneurs, like Todd French and Dan Miller, who try to advance the methods of boatbuilding. But I am a yacht designer. And I design yachts that bring jot to folks who own and sail them. My greatest joy will be when you  choose to own a  LEVANT 15 , and tell me how much it has enhanced your life.

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Boat Building in "Cold Moulded"

Moulded Ply or Veneer

From full size patterns supplied with the plans , station frames are marked and cut out of scrap timber and plywood. Stringer positions are marked and notched. The frames are erected on a prepared strongback and the stringers, keelson and stem are added.

Very little fairing off is necessary as the stringers go in at the correct angle and allow the plywood or veneer strips to be added glued and nailed to the stringers.

The plywood or veneer strips are applied diagonally and sometimes vertically and fore and aft as shown in the plans.

BUILDING TIP: When installing veneers or other material that requires temporary staples, one of the most onerous jobs is removing the staples. Many methods have been tried but this one successfully used by Russ Stevenson works well....buy some narrow THIN packaging METAL tape and this can be used underneath the staples....easy to remove when the glue has set...simply give a hefty tug on one end of the tape and the staples come out without a whimper...make sure to wear goggles as staples may fly in all directions.

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• Yachting World
• Digital Edition

LA 28: The modern trailable boat that’s cold-molded from mahogany

• October 8, 2019

The LA 28 is a beautiful, cold-moulded wooden trailer-sailer that was designed to be unique, and has now sold nine boats across Europe. Sam Fortescue steps on board

Appropriately, it’s a long train ride through thick, thick forest before I reach the LA Yachts yard on the banks of Lake Müritz in central Germany. This seems apposite because the boat I’ve come to see is an exquisite example of how wood is just as relevant as ever when it comes to boatbuilding.

In truth, the LA 28 has little in common with the endless rows of fir that fringe the lake; she is cold-moulded from nobler stuff. But it is striking that this young shipyard chose to build in wood. I ask yard owner Lothar Fichtner why.

“It’s lighter than GRP and cheaper than carbon,” he says without blinking. So much for the romance of traditional construction, then. In fact, there’s little about this vessel the boatbuilders of 100 years ago would recognise.

Around 60kg of Sicomin epoxy is used in the lay-up. Photo: Soenke Hucho

For one, cold moulding is a technique that relies heavily on epoxy resin to stick each layer of wood to the last and sheath the whole structure to keep the water out. Then there can be as much or as little carbon in the rig and the finish as you want, while propulsion comes courtesy of a Torqeedo electric motor.

Despite her elegant tumblehome and the plunging curve of her coachroof, this is a thoroughly modern boat. “The best of modern and traditional,” Fichtner says.

The story of the LA 28 begins with the desire of a wealthy man to have a beautiful sailing toy. Lothar Fichtner was that man and, having sold his engineering business, he wanted to enjoy more of life from his second home on Mallorca.

Article continues below…

Revolver: Bruce Ritchie’s gentleman’s racer blends traditional and modern craftsmanship

“I wasn’t expecting this,” said Michael Ritchie when his 83-year-old father Bruce showed him the lines he had drawn up…

European Yacht of the Year 2019: Special yachts

This category assembles a varying mix of interesting craft, many of which we might otherwise not have had the chance…

He approached a boatbuilder in the Muritz region called Andreas Zehle who specialised in the building of the German 20er Jollenkreuzer racing dinghy class, also cold moulded. Then he drafted in designer Martin Menzner from Berckemeyer Yacht Design in Laboe on the Kieler Fjord.

This small design house has worked on everything from dinghies to high-latitude yachts, using a range of construction materials and techniques. Crucially, Berckemeyer is strong in cold-moulded yacht design, or ‘speed strip’ as they call it.

The brief was for a trailerable 8-9m boat, that was “simple to rig, as single-handed as possible and with excellent sailing characteristics,” Fichtner explains. “I am bothered by the current development in boatbuilding. Almost all boats look the same. I wanted something exclusive that is modern in design and traditionally built.”

It takes more than 15 coats of varnish to achieve this degree of shine on the finish. Photo: Soenke Hucho

Menzner is a successful J/80 sailor himself, and the two men quickly saw eye-to-eye. The whole design process took just three months. Fichtner had no clear idea of it at the time, but he wasn’t just buying a boat, he was establishing a yard.

“I founded the shipyard because two boatbuilders were unemployed and I wanted to have a boat for my area in Germany and Mallorca,” he recalls. But one thing led to another, and Fichtner is a naturally ambitious man.

“We had a lot of success at trade fairs and continuous orders. Then I found my way into Germany’s Yacht magazine.” They have now sold nine boats since 2015, when the first garnered rave reviews at Interboat in Friedrichshafen.

Working with wood

Cold moulding requires a rough plug to be made, but no female tooling is needed, making it much cheaper to set-up than in the case of GRP or carbon. The plug around which the hull is formed is simply made from strips of softwood fastened around CNC-milled frames. It’s quick, cheap and relatively easy. The natural flexibility of the 2.5mm strips of wood used in cold moulding the hull iron out any imperfections in the mould.

The first stage of the process is to place a layer of plastic sheeting over the mould. Then the strips are bent into shape and clamped in place to hold their form. Each layer is bagged and vacuum infused with Sicomin epoxy resin, which soaks into the very top layer of the wood and helps to bond each strip edge-to-edge.

Each layer is laid in a different direction to the previous: longitudinal strips of okoume first, then lateral, then diagonal. For the outer layers, Lothar prefers African mahogany (khaya), giving a warm, reddish finish to the hull, which is many times stronger than the equivalent in glassfibre, and lighter too.

The deep curve of the tumblehome is all part of the hull shape, so it isn’t possible to mould the whole hull at the same time. Instead, there are two symmetrical plugs, one for the port side, one for starboard.

When the two halves are finished, they are simply epoxied together in the middle with a sort of low keelson covering the whole length of the joint for extra strength.

Cold moulding leads to a beautiful interior finish. Photo: Soenke Hucho

At this stage, the hull is still just a hollow form, albeit a beautiful one. Extra strength must be added next, which is achieved by ‘backfilling’ frames, ringframes and stringers – all glued into place after the event. These support the stresses of the mast, the shrouds and the keel, and provide structure for the transom, keelbox and so on.

The finish is a matter of personal taste – every owner makes their own decisions on this. Some have opted for carbon detailing; a layer of carbon epoxied around the aluminium mast post, for instance, a carbon keelbox and carbon fibre pads where the line for the retractable bowsprit passes through the companionway bulkhead into the cockpit. The mast and boom are both in carbon, with sails recommended in X-Drive carbon from UK Sailmakers.

Others have requested a white painted interior (a lot more work, observes Fichtner), or different woods used in the construction process to give a slightly different finish. The point is that every boat is unique and can be formed and specified to fit its new owner’s wishes: engine or no engine; spade rudder or transom-mounted kick-up rudder.

LA Yachts uses a very light wooden core for the tiller, then laminates it with carbon fibre. Photo: Soenke Hucho

Below the waterline the usual keel is a 600kg lead bulb, but again you can choose from a number of options. With the fixed keel there is the option of a 1.7m, 1.8m or 1.9m draught – depending on where you sail and how aggressively rigged she is.

But the hydraulic lift is proving a popular option, which reduces draught by 0.9m in the raised position. It’s a handy option for shallow waters, and makes it more feasible to land wherever the fancy takes you – perhaps with a family and a picnic basket.

True to the boat’s thoroughly modern character, Fichtner worked closely with Torqeedo in designing the LA 28 to use one of the company’s 2.5kW electric drives.

This is permanently mounted on a pod under the cockpit, but the throttle lives out of sight on a fold-down panel that pops out of one of the cave lockers. It’s a neat solution to the fact that the Torqeedo control is chunky and modern, and rather at odds with the otherworldly lines of the LA 28.

Controlled growth

The boat is resolutely designed to be simple to handle. “They sail easily and they’re very light. I can come into port by myself, and handle her myself,” Fichtner says. “With a bigger boat you always need a team – you are never alone.”

That said, there is a bigger boat on the horizon. Taking its cues from the look and handling of the LA 28, a larger 35-footer has been designed and will shortly enter the build phase. At 10.8m long, she can still be trailered, thanks to an all-up towing weight of just less than 3.5 tonnes.

“I want to invest in quality,” says Fichtner determinedly. “My dream would be to build just three boats per year.” There seems to be a preponderance of billionaires among the ownership ranks of LA Yachts, so perhaps three a year is more ambitious than it sounds.

Specification

LOA: 8.8m (28ft 11in) LWL: 8.0m (26ft 3in) Beam: 2.5m (8ft 2in) Draught: 1.7-1.9m (5ft 7in-6ft 3in) Keel raised: 0.8-1.0m (2ft 8in-3ft 3in) Displacement: 1.5 tonnes Ballast: 600kg (1,322lb) Engine: Torqeedo Cruise 2.0FP Price: €120,000 (ex. VAT)

• SPECIFICATIONS

The second yacht in the LM46 line of performance cruisers features a 7’7″ keel for top performance on the racecourse and a second head for increased comfort while either cruising or racing. Arcadia was launched in the spring of 2022. The yacht’s owner, an experienced racer, plans to enter the vessel in some of the most famous ocean races, including the 2022 edition of the Bermuda Race.

LM46 Hull No. 2, like every yacht in the LM46 series, is a high-performance, cold-molded sailing yacht that features the comfort and ambience of a wooden boat but delivering 10 knots of speed under both sail and power. The LM46 is a collaboration between Lyman-Morse founder Cabot Lyman, his son and company president Drew Lyman, and top Kiwi designer Kevin Dibley .

Specifications

• displacement 24,250 pounds
• fuel capacity 81 gallons
• water capacity 156 gallons
• type Sail - 1,183 sq. ft.
• designed by Kevin Dibley
• builder Lyman-Morse Boatbuilding Co.
• construction Cold-molded wood composite
• hull material Douglas Fir/Western Red Cedar
• configuration Sloop
• location Thomaston, Maine
• boat engine Yanmar 4JH80
• horsepower 80 hp

Whiskey Plank Installed

Construction is moving along quickly.  The crew recently celebrated the installation of the Whiskey Plank in Hull #2 of the LM46.  This second hull in the LM46 cold-molded performance sailboat series is scheduled to launch this summer.

Performance

LM46 Hull No. 2 features a powerful cruising rig with swept-back spreaders and 1,183 square feet of sail, including a squaretop main, that gives the LM46 an impressive turn of speed. Rolling out the optional asymmetrical spinnaker steps thing up a notch and lets the yacht hit speeds of 10 knots or more. When conditions are right, this yacht can click off 240 miles per day, while the wooden hull, 43’ waterline length, and comfortable displacement-length ratio of 133 allows for one-handed steering or easy steering by autopilot, no matter the weather. Equipped with a 7’7″ fin keel, LM46 Hull No. 2 will stand up to the most strenuous conditions whether racing offshore or family cruising along the coast.

Like everything else aboard the LM46, sail-handling is kept simple, efficient, and user-friendly: roller furling for the jib, a detachable staysail, and a mainsail furling system that is fast, easy, and effective. Following the French lead, we’re keeping weight out of the bow of the LM46 by using almost all anchor rode instead of chain. Quiet, easy — just like the LM46 itself.

And while LM46 Hull No. 2 will excel under sail, it can also deliver its crew just as swiftly under power, with an 80-horsepower Yanmar diesel powering the yacht at up to 10 knots.

Layout & Design

One word sums up the layout and design of the LM46: Soul. Too many boats built and bought today lack this key element, but by carefully considering every aspect of this new yacht – including the hull material itself – boatbuilders Cabot and Heidi Lyman and yacht designer Kevin Dibley have created a boat that is ingenious in its simplicity, efficiency, and performance.

The spacious cockpit features 6’5″ seats, ideal for accommodating guests or, when the weather is right, a night of sleeping under the stars. Twin helms offer unrivaled visibility, while the drop-down transom affords no-step access to and from the dinghy. All sail-handling is easily managed without ever leaving the cockpit.

Step below and enjoy a seat in the spacious salon and take in the V-groove overhead and combination of painted and bright-finished bulkheads and trim – you’ll instantly find yourself transported from your daily life to somewhere quieter, simpler, more elegant. The wraparound galley, designed using the lessons Cabot and Heidi learned during 16 years of living on their boats around the world, is as appropriate to preparing a three-course dinner as it is for mixing up a batch of evening cocktails. Aft, to port, a second head and wet locker provide easy access for guests or crewmembers coming off watch. The aft full berth to starboard makes for a welcoming guest cabin or, when offshore, the ideal sea berth.

Moving forward, to starboard you’ll find a separate head with vanity and a shower. The huge forepeak aboard LM46 Hull No. 2 includes a vee berth that converts into a centerline queen and storage for a weekend or a month’s worth of clothes and gear. Here, as everywhere aboard the LM46, you’ll be struck as much by what you see as what you don’t – we’ve included everything that you need and nothing that you don’t (watermaker, A/C, excess electronics).

Sails & Rigging

• Fully battened squaretop main
• Asymmetrical spinnaker (optional)
• Staysail (optional)
• Code Zero (optional)
• Mast – Carbon (air clearance of 63’10” allows access under ICW bridges)

Sail handling:

• Primary and secondary sheet winches, easily reached by helmsman and crew with the ability to stand and grind without leaving the cockpit
• Halyard winches – Electric (optional), also used for reefing lines, located on cabinhouse top
• Spinlock jammers/clutches

• 78-gallon custom stainless water tanks (2)
• 81-gallon custom aluminum fuel tank
• Polyethylene Vetus holding tank
• Tecma marine head
• Life preservers (optional, Spinlock vest-type)
• Sailing instruments
• Navionics plotter on GPS-enabled iPad
• Broadband radar -12-mile range
• LED lighting throughout
• Marelon seacocks by Forespar
• 120-amp engine alternator
• Jabsco anchor washdown pump (optional)
• Groco Sea Strainers
• Centek muffler, with stripper for silent charging
• 4″ blower for engine compartment
• Scott vented loops
• Rule and Whale automatic bilge pumps
• Whale manual bilge pump (near helm)
• Seadog deck fills and pumpout deck fitting
• Perko hinges (head door)
• Cushions – mid-density foam with ultrasuede covers on seats, canvas on berths
• Feathering propeller by MaxProp
• Isotemp hot water heater (plumbed to engine)
• Force 10 propane stove, with Trident controls and detector
• Espar heater (optional, for those in higher latitudes)
• Jabsco pressure water pump
• Lewmar low-profile deck hatches
• 640AH Lithium Phosphate batteries (optional) for unlimited cycles
• 44 lbs CQR anchor, equipped with 20’ of 3/8″ chain and 150’of 3/4″ Yale Brait anchor rode
• Lewmar anchor windlass
• Blue Seas electrical panel at navigation station, with 12VDC  and 110 AC breakers
• Isotherm refrigerator/freezer, with evaporation plates
• Polar stainless double galley sink
• Scandvik faucets

Construction

The LM46 uses modern design and technology to improve upon the most sustainable building material ever created: Wood. Wooden boats 70 years old or more are still winning offshore and coastal races, sailing over many horizons, and, when necessary, are far easier to bring back to life after years of neglect. The Douglas Fir and Western Red Cedar planks that comprise the LM46’s nearly 1”-thick hull are sustainable, originating from sound growth- and forest-management plans and thousands of years of experience. Using the cold-molded building process results in a hull that delivers a quiet ride underway and is both flexible and incredibly strong. A layer of glass on the topsides increases durability and reduces maintenance. Wisely employing modern building materials and techniques and eliminating excess electronics allows us build a low-maintenance yacht that breaks the cycle of having to travel from boatyard to boatyard to keep a yacht in top condition – an ironic claim for the owner of a service yard to make, we’ll admit!

Lyman-Morse’s intelligent use of its Haas GR712 Computer Numerical Control (CNC) machine to cut planks, bulkheads, and joinery reduces costs for the hull and deck construction, but we have not thrown out the baby with the bathwater in the LM46. The cockpit, deck, and cabinhouse, often the site of water-infiltration in older wooden boats, feature a composite structure that keeps things bone-dry belowdecks. To use anything other than modern materials in these locations would be irresponsible.

Whenever possible, all items for the LM46 are built as modular units outside the boat – the same system used by wooden production boatbuilders half a century ago and somehow forgotten. We use such time-tested processes, combined with expert Maine shipwrights and high-tech tools such as lasers and 3D printers, to create a construction plan that is competitive with production boats but that yields a yacht that is meaningful and carefully constructed – a world apart from the fiberglass cookie-cutter boats that fill marinas and boat shows these days.

LM46: Putting the Real World in Perspective

The LM46 doesn’t deny the “real” world – it puts it in perspective.

More than 170,000 miles of sailing together, including a three-year circumnavigation with their three boys and numerous offshore races and trips to the Caribbean and the South Pacific, has shown Cabot and Heidi Lyman one thing: Boats have become too complicated. As the founders and owners of the world-renowned Lyman-Morse Boatbuilding Company for the past 42 years, they’ve built over 110 vessels, many of them equipped with watermakers and digital screens of all shapes and sizes. For many of us, all that gadgetry just distances us from why we started sailing in the first place: Reconnecting to a simpler way of life. Our day-to-day lives have become consumed with devices, passwords, and updates. Over time, our boats have tried to keep pace instead of providing an escape, a place where you can forget the world and simply enjoy. The LM46 changes that.

Spectacular in its simplicity, powerful in its performance, unparalleled in its quality.  Contact us today  and make the LM46 a member of your sailing family.

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Sanford Boat Company was established in 1977 to reproduce Nathanael Herreshoff's magnificent Alerion design in modern wood cold-molded construction. We present the result, our ALERION CLASS SLOOP , as the world's finest day-sailor. She has been in our production for 40 years over which time cold molded wood has been accepted as the premier technique for building yachts.

Alfred Sanford, principal of Sanford Boat Company, has sailed his S&S yawl for many years around the North Atlantic and European waters. IMPALA is a classic design, of plank on frame wood construction,. Her adventures show her, in many ways, superior to the modern cruiser, and inform Sanford Boat's work.

Sanford Boat Company, a pioneer of cold-molded wood construction, has continued its research in advanced wood construction techniques, seeking to make the process stronger, more robust and more economical. We focus on offshore designs, called MAGIC CLASS , optimized for gunkholing.

Sanford Boat Company offers BOOKS and bibliographies relative to its work.

Custom cold-molded wooden boat construction The 34' Odyssey Client Galleries Our Construction Process The crew, well versed in old-world craftsmanship and building techniques (the skill-set that is at the foundation of Van Dam Custom Boats), also embraces technology and innovative design as an integral part of the future of custom wooden boat building. Technology, at the hands of a master, will not strip away the intricacies of custom handworkings in wood, but will assist in making it last longer and perform better. A balance is reached between function, performance and beauty. Our processes envelop them all. Wood Composite Construction It has been called a master craftsman’s art form. At Van Dam Custom Boats, we use the process of wood composite construction to build all of our one-in-the-world watercraft. This process involves the utilization of epoxy adhesive to laminate many thin layers of wood together – creating the hull and structural elements of our boats. By marrying legacy craftsmanship with sound engineering principles, we are able to construct vessels that are stronger, lighter and more durable than boats built via other methods. Van Dam Custom Boats are built for generational enjoyment and constructed to stand the test of time. In the design phase we shift from 2D drawings to 3D virtual models, using state-of-the-art 3D computer aided design (CAD) software to detail every inch of your boat. Propulsion, systems and construction details are married with style and concept. There’s still plenty of creative work to be done here as the space evolves and design opportunities present themselves. Systems Design Every Van Dam boat requires its own unique systems package to meet the owner’s expectations of performance, function and capability. Whether it’s Garmin, C-Zone, Humphree, Seakeeper, Volvo or future technology, we design, program and thoroughly test each system to ensure they complement one another and operate in unison. Innovations At Van Dam, we continuously explore new horizons in recreational boating. Drawing inspiration from the automotive, aviation, and marine sectors, we integrate cutting-edge principles of design, engineering, and construction into our projects. Whether it’s pioneering digital switching systems, wake-adapted rudders, or advanced lighting solutions, we have the expertise to turn innovative ideas into reality. Hand Cut Lumber Every board that goes into our custom builds is craftsman selected and carefully sorted by characteristics that will dictate whether it is used for structure, cosmetics, or in some cases both. Each is hand cut and hand bent per design specifications, while attention is given to book matching the grain throughout the construction. Our wood is used as a unidirectional fiber as it is much stronger along the grain than it is across the grain. Engineering takes full advantage of this characteristic and while such precision takes time, it is what separates a Van Dam Custom Boat from others in the industry. Artistry and functionality carry over to our metalwork, with intricate craftsmanship being a company wide offering. From hand polished cutwaters to custom shaped seating and framing adornments, all metal work is skillfully created on site. Design revisions, or improvements to performance, are made at the hands of our metal craftsmen, utilizing their natural talents and the state-of-the art equipment at their disposal. Paint & Varnish Finishing the areas of each boat that will rarely be seen, with the same care and meticulous standards as our mirrored exteriors, is one of many attributes that sets Van Dam Custom Boats apart in the world of custom wooden boat building. It not only guarantees the longevity of quality and function, it affords you peace of mind – your commission is of top-of-range craftsmanship, inside and out. It is not about simply finishing the build and moving on to the next project. It is about you, your expectations and your future enjoyment on the water. We are no less meticulous in our approach to mechanical and electrical component construction. Power, performance and ease of use are integral aspects of your boating experience and Van Dam Custom Boats recognizes this area as a craft unto itself. Master Certified craftsmen in systems and electronics create and assemble the perfect inner workings, allowing you to control your boat effortlessly, safely and with confidence. Pay attention to the details. Do the little things right so the big things work out. The best place to go with your idea for a dream boat is Van Dam Custom Boats. We were impressed as much with the total experience as we were with the end result. WOW’s on and off the water.” – Chocolate Chip 3 Owner $ 0.00 0 items Carolina 25 $ 750.00 – $ 4,750.00 The Carolina 25 is a classic North Carolina sport fishing boat design in a trailer-able center console layout. This design features the famous Carolina flare, broken shear and tumblehome that is sure to turn heads.  This boat is built using the cold molded method and best suited for those with boat building or woodworking experience. Looking for more photos? Want to connect with others who have built this boat?  Check out the Salt Boatworks boat builders group, HERE! Boat Plans include prints detailing assembly of the boat and full size templates to trace and cut all jig parts. Jig Kit includes prints detailing assembly of the boat, plywood jig parts CNC cut, and HIN assignment. NOTE:  Jig components include stringers, transverse frames, bulkhead, transom, stem, bracket plus temporary structure.  We do not include all plywood like the FRS series because hull side and hull bottom are cut to fit during assembly using the cold mold method. Jig Kits are shipped by motor freight or can be picked up from Morehead City, NC.   Shipping will vary by destination and you should contact us for a quote  BEFORE  placing an order if you plan to have the kit shipped.  Some ball park costs from past shipments are ~$600 for South Carolina and ~$800 for southern Florida and Texas. Orders placed here can only ship within the USA at this time.  If you are outside of the USA, please send us a message on our contact page for a shipping quote. Description Additional information. Reviews (1) Our Carolina 25 is a classic North Carolina sport fishing boat design in a trailerable center console layout. This design features the famous Carolina flare, broken shear, and tumblehome that is sure to turn heads.  The bottom shape is that of a traditional “Carolina” bottom with 18 degrees of dead rise aft and a sharp V at entry for a smooth and efficient ride with stability at rest.  There are no interior compromises either, a single level floor all the way forward and a large single fuel tank which allows a step down inside the console makes a spacious and easy to navigate interior. Powered by single or twin engines this boat will take your family to the sand bar or off shore to the fish! This boat is built using cold molding and is recommended for those with boat building and/or wood working experience. Available as a pre-cut jig or full size patterns, both options include detailed assembly drawings, making it easy to build a boat of your own. 28’0″ LOA (including bracket) 25’2″ hull length 8’6″ beam (trailer-able width) 18 degrees dead rise aft 17″ hull draft @ 6000 lbs 140 gal fuel capacity (single tank) 350hp (30″ shaft) or twin 200hp (25″shaft) Cruise 30-35mph, single 350hp runs ~40mph and twin 200hp runs ~45mph Single level / flat deck full length of the hull Can be built as a center console or express with cabin Material Estimates for Hull: Jig Kit: 9 sheets marine grade plywood 1/2”x4’x8′ (stringers, transverse frames, bulkhead) Jig Kit: 5 sheets marine grade plywood 3/4”x4’x8′ (transom, stem, bracket) Jig Kit: 5 sheets standard plywood 1/2”x4’x8′ (temporary structure) Strong back : Pine – 2 boards 2”x6”x16′, 2 boards 2”x6”x14′, 3 boards 2”x6”x10′, 5 boards – 2”x4”x8′, 6 boards – 2″x4″x10′ Bottom : 12 sheets of marine grade plywood 3/8”x4’x8′ Sides: 18-20 sheets of marine grade plywood 1/4”x4’x8′ Floor & Gunnel: 8 sheets of marine grade plywood 1/2”x4’x8′ Ceiling: (optional) 7 sheets of marine grade plywood 3/16”x4’x8′ Keel: Fir – 6 boards 2”x4”x8′ Stringers: Fir – 4 boards 2″x6″x16′ (board) Sheer: 200 linear feet of Juniper or Fir 3/4”x1” & 100 linear of Juniper or Fir at 1/2”x1” Rib Bands: 180 linear feet of Juniper or Fir 3/4”x1” Chine: 250 linear feet of Juniper or Fir 3/4”x3” OR 3/4” marine plywood cut in 3″x8′ strips Sheer Bumper: 140 linear feet of Fir or Sapelle 1/2”x1-1/2” Spray Rail: 50 linear feet of Fir or Sapelle 3/4”x1-1/2” Floor Supports: 200 linear feet of Juniper or Fir 1.5”x1.5” Resin: 30 gallons of marine grade epoxy resin (DO NOT USE POLY OR VINYL ESTER RESINS) Glass: 250 linear feet of 1708 bi-axial fiberglass 50” wide Filler: 5 lbs of fumed silica or similar for fillets Questions about Boat Building?   Check out our FAQ Weight 1 lbs Dimensions N/A Kit Includes CNC cut plywood, Prints detailing assembly of the jig, Plywood and dimensional lumber selection guide Carolina 25 Option Boat Plans w/ Patterns, Boat Jig Kit 1 review for Carolina 25 Kyle – October 10, 2019 I am a couple months into this build and can say that the plans are very well thought out and precise. One of the major advantages of these plans is that you will have most of the flooring framework done as well when fully assembled. There is a LOT of cutting for this jig, but it is a 25′ boat with a bracket. You can save about 80 hours of cutting by ordering the pre-cuts. So far I remain impressed and excited to get her done. You must be logged in to post a review. Related products Flats River Skiff 16 Flats River Skiff 12 Core Sound 21 Projects: Building with the cold-moulded method After an unfortunate motorbike accident, Harry Evans was forced to put his boating career on hold. However, an opportunity to train as a boatbuilder at the Boat Building Academy  in Lyme Regis has given him a fresh start. Here, Harry tells us about his work at the college to build a Clinker sailing boat, which he’s called ‘The Last Leg’. How did the project come about? Building a boat is a key part of the training here at the Boat Building Academy Lyme Regis. It was such an exciting prospect to get back into the practical side of things after the accident. The Last Leg was initially intended to be a traditional Clinker. However, to make things more interesting I decided to build it using the cold-moulded method of construction. Which WEST SYSTEM® epoxy products did you use? How did they help? I used WEST SYSTEM epoxy products throughout the build, as I believe they’re the most efficient and reliable. The WEST SYSTEM 30kg C pack plus the corresponding pumps were great. The pack gave me both 105 Epoxy Resin® and 205 Fast Hardener® , while the easy-to-use pump system was quick, accurate and took the guesswork out of time-pressured college tests. I also used WEST SYSTEM 406 Colloidal Silica – it’s a fantastic thickening agent, very strong and hard. The WEST SYSTEM 409 Microsphere Blend low density filler was easy to use and shape. Finally, I used WEST SYSTEM 740 Glass Fabric , a 135g/m² plain weave glass cloth which is essential for water-tightness, strength and resistance to abrasion. What did you learn about the cold-moulded method whilst doing this? I would definitely recommend giving serious consideration to cold moulding and epoxy as a construction method – it’s fast and very strong. For a start, the cold-moulded method was a lot quicker than the traditional method of Clinker construction; we managed to fully plank the hull and have it watertight in approximately three weeks. What’s more, you can really see how lightweight and strong modern epoxy-wood methods are. Using epoxy enabled us to create a smooth hull with a monocoque structure, eliminating the need for through-hull fastenings and calling for fewer reinforcements. All in all, compared to traditional methods, the cold-moulded method is very satisfying, relatively trouble-free and produces a low maintenance boat that will have a long life in the water. What was the most rewarding part of the project? It was incredible to see how fast and strong the cold-moulded wood-epoxy method can be. It was also great to be working as part of a team. We are all looking forward to finishing the boat and seeing it in the water. What’s your top tip for boatbuilders looking to start a similar project? Manage your time well and source materials that you can trust – make sure you do your research. Apart from that, just go for it! Our thanks to Harry Evans for his contribution. You can learn more about the Boat Building Academy  at Lyme Regis on their  website . Do you have a project that you’re working on? Email us at [email protected] and we could feature it in a future edition of epoxycraft! Want to know more about the products mentioned in this article, including the full range of WEST SYSTEM epoxies? Visit the WEST SYSTEM  website . Back to projects Willett Built Restores J24 Classic Boatbuilding in Oslo Repairing Minor Cracks & Holes in a Fibreglass Boat Visit our Popular Forums Monohull Sailboats Multihull Sailboats Powered Boats General Sailing Antares Yachts Fountaine Pajot Lagoon Catamarans Cruising Business Boat Classifieds General Classifieds Crew Positions Commercial Posts Vendor Spotlight Life Aboard a Boat Provisioning: Food & Drink Families, Kids, & Pets Afloat Recreation, Entertainment, & Fun Boat Ownership & Making a Living Liveaboard's Forum Seamanship, Navigation & Boat Handling Seamanship & Boat Handling Training, Licensing, & Certification Health, Safety, & Related Gear Rules of the Road, Regulations, & Red Tape Engineering & Systems Const. / Maint. / Refit Product / Service Reviews Electronics: Comms / AV Electrical: Batts / Gen / Solar Lithium Power Systems Engines & Propulsion Propellers & Drive Systems Plumbing / Fixtures Deck Hdw: Rigging / Sails Aux. Equipment & Dinghy Anchoring & Mooring Photo Categories Member Galleries Life Onboard Sailing in the Wind Power Boats Cruising Destinations Maint. & Boat Building Marine Life Scuba Diving & Divers General Photos Recent Photos Listing Categories African Cats view more » Crew Wanted Crew Available Enhance Your Account Meet the Mods Meet the Advisors Signup for The Daily Cruiser Email   > > Please support our sponsors and let them know you heard about their products on Cruisers Forums. 28-02-2009, 07:09   Boat: C&C 38' . In particular I have come to believe that a cold molded is very different from a traditional wooden boat. I believe that a traditional wooden boat will take more time for than I am prepared to give it. use as a big part of the total material package, but the cold technique seems to me to be more of a composite material than just a cored panel like in a or of an otherwise boat. are one of a kind and many are amateur built. This tends to keep the prices lower for boats built using the cold technique, particularly for amateur built boats, than a comparable boat of fiberglass construction. by a skilled in analyzing cold molded boats can be relied on to give good . nightmare or is it comparable to a fiberglass boat in terms of maintenance? 28-02-2009, 07:55   Boat: PDQ 36 & Atlantic 42 . I a cold-molded sailboat was built to be dropped from an airplane to let downed pilots sail away to . That's tough. But like , if penetrates one of the wood layers, results, if only in the one contiguous sheet or stick of wood. Subsequest freezing and thawing cracks the resin or glue and the (now fortified with wood-eating enzymes) reaches the next layer. The WEST system tends to isolate water penetration by using smaller pieces of wood. If scrupulous care is taken to seal any new access points (thruhulls, screws, bolts, etc.) water can't find a place to start. So if you do that, and never hit anything hard enough to crack something, its great! But: If its built by anyone but the most meticulous craftsman, or it has been around long enough to have experienced normal wear and tear, a will find water with his moisture meter or his highly calibrated plastic mallet. Then you just have to dig out the wet wood, shape a perfectly fitting new piece of the same wood, glue it back in with uniform pressure, and refinish the surface. Fiberglass is more forgiving, easier to fix and cheaper all around. Wood is beautiful, and a renewable resource. Your choice. 28-02-2009, 08:18   Boat: Benford 38 Fantail Cruiser as FRP... perhaps easier and certainly no more expensive. PS. I use a brass hammer ( uncalibrated 28-02-2009, 09:27   from practical experience I'd say that if you use good raw materials (I mean high quality wood, grade , good etc.) and do the carefully, then this boat will serve you well and require no more care than a fiberglass boat; in fact, the only you must keep up to is: dry - which is not a bad idea in any case ! such , IMHO, is also stronger, nicer, and gives more inside comfort than fiberglass. 28-02-2009, 09:36   Boat: Pearson 422 certainly sounds good, the beauty and benefits of wood without the headaches. I have read that cold molded have much better insulating properties than glass so warmer in cold climates, less , etc. 28-02-2009, 09:48   cold molded have much better insulating properties than glass so warmer in cold climates, less 28-02-2009, 10:32   Boat: It’s in French Polynesia now       28-02-2009, 10:43   Boat: Farr 46 . Triple skin kauri hulls were being built in NZ more than 100 yrs ago and are still sailing today - have a look at in the 1950's this advanced onto glued construction of 2 or 3 skins over laminated frames & stringers, later still in the 80's the frames were substituted with a thicker longitudinal skin with one or 2 diagaonals over, typically covered with a light glass cloth and resin. Few problems with the hulls, only if freshwater was trapped by stringers, more problems where plywood was used for the decks with holes not being sealed properly 28-02-2009, 10:49   Boat: It’s in French Polynesia now 28-02-2009, 11:36   Boat: Custom Finch 46 - Airielle didn't reveal any issues. The fellow was very thorough in tapping the hull. Granted, because cold molding is not well known or understood, it probably scares many potential boat buyers away. That is too bad, because they can be incredible . 28-02-2009, 14:04   Boat: Jon Sayer 1-off 46 ft fract rig sloop strip plank in W Red Cedar , despite the worry evidenced above, are not particularly difficult when compared to GRP. If ease of is your criterion, then go for -- weld it up anywhere. And yes, as always, a boat built by a really good shipwright will be better than one built by someones' little brother who flunked wood shop. And that applies equally to any form of construction! The need for a comprehensive survey is equal to any other sort of construction. The findings of an expert who isn't suffering from boat lust should guide us all before signing that line. So, if you find a good cold molded or strip planked boat, you are indeed in luck... go for it! Cheers, Jim and Ann s/v Insatiable II lying Gladstone Qld Oz 28-02-2009, 15:25   Boat: Searunner 34 and Searunner Constant Camber 44 28-02-2009, 15:27   Boat: C.L.O.D. if allowed to collect and the area is not well ventilated. However having to choose between a well made strip planked and a well made cold molded boat could be a huge problem - I am not sure if you could ever be sure that one was better than the other - both are near perfect IMO. 28-02-2009, 22:15   Boat: 34' Searunner Tri was as good as the day it was launched.....it si a wonderful method of boat building.     01-03-2009, 09:37   cannot seem to get their heads around is that a traditionally built boat was a disposable item. Solid wood was (in many places) , labour was cheaper, and everything that wasn't wood was salvaged - even the nails. In that economy you built a boat knowing it was going to be replaced within 10 years - sometimes even within a voyage. The need for cold-molded boats arose first from a desire for speed - they were lighter. Then because they required less-skilled labour. And now, as we try to build boats to last a half-century or more, because they can be long-lived. But they aren't going to last as well as the mostly-inorganic and inert fibreglass, and they aren't going to be as as the unschooled and unskilled yard employees or the fibreglass factory robots. A couple I knew threw together a gorgeous carvelle hull in 3 months. They went from paper drawings to the in just over 3 years, and they spent a bit over $30k. Their boat won't last, and they planned to sell it when it's 10 years old or whenever they get back, whichever comes first. I haven't heard from or about them for 7 years, but I'm not sure, if they'd decided to build their boat cold-molded and to furniture standards, they'd be on the water yet. Wood is a wonderful material. It can outperform pure carbon fibre in some composites. But it isn't holy, and you need to keep the goal in mind. Thread Tools Rate This Thread : Posting Rules post new threads post replies post attachments edit your posts is are code is are are are Similar Threads Thread Thread Starter Forum Replies Last Post alanvdh Monohull Sailboats 50 11-02-2011 14:42 READY2GO General Sailing Forum 17 02-01-2010 20:50 aboutgone Monohull Sailboats 4 12-08-2009 22:10 indypopeye Multihull Sailboats 0 29-01-2008 09:17 irwinsailor Great Lakes 8 06-04-2003 05:48 - - - - - - - Privacy Guaranteed - your email is never shared with anyone, opt out any time. Boat Plans | Books | CD's | Downloads $ 0.00 0 items The New Cold-Molded Boatbuilding $ 30.00 Description Additional information. Reviews (0) It’s generally agreed that cold-molded construction is the best method for the amateur or independant professional interested in building a full-size cruising sail or power boat. A truly appropriate technology, cold molding combines the beauty of wood with the low-maintenance characteristics exceeding those of fiberglass. The New Cold-Molded Boatbuilding is the complete, soup-to-nuts presentation of process, with chapters detailing every facet of construction from choosing a design and setting up, through engine installation and wiring, to launching a design and performing sea trials. In addition, the author has streamlined the cold-molded process considerably, producing boats that are more economical, efficient, and sturdy–Boats built from native materials that will last the life of the builder and turn heads in harbours around the world. Weight 32 lbs Dimensions 12 × 12 × 1 in There are no reviews yet. Only logged in customers who have purchased this product may leave a review. Related products Catalogue Of Power Boats The Voyages Of Fishers Hornpipe Catalogue Of Cruising Designs My Second Cruising Sailboat — TERESA THE LORCHA 50 T’IEN HOU THE MAYOR OF JOE’S SOUND, BAHAMAS THE PILOT SCHOONER 40C THOMAS CLAPHAM AND THE ROSLYN YAWL Login to my account Enter your e-mail and password: New customer? Create your account Lost password? Recover password Recover password Enter your email: Remembered your password? Back to login Your cart is empty 15' Cold Molded Catboat--MARSH CAT Description. Be sure to select PRINT or DIGITAL when you order. Her 6'11" beam makes for a big 15-footer. Cold-molded (four 1/8" layers of mahogany), lightweight and trailerable. Designed by Joel White LOA - 15' LWL - 14' Beam - 6' 11" Draft (cb up) - 9" (cb down) - 2' 5" Displ. - 1,309 lbs. Sail Area - 152 sq. ft. Construction: Cold-molded No lofting is required Skill level: Intermediate Plans include 6 sheets. More info: click MATERIALS LIST . And, if you would like to see some more about building, click our RESOURCES page, and scroll to the Building Projects section.  Here's a video on Marsh Cat from our sister publication Small Boats Monthly And, from that Small Boats Monthly feature is this pretty photo of Marsh Cat, taken by builder Kevin McDonald. He built her using strip construction, 5/8" x 1" Western Red Cedar. If ordering Digital plan sets: These files are in PDF format.  Some designs will have just a single page needed to be printed on large paper... typically if they had full-sized mold patterns. Other pages could be printed on letter or tabloid size paper, if you want to save printing costs. You'll see a measurement on pages that have full-sized drawings, so your local print shop will just need to print to that size. ———————————————————— “Your downloads are ready” will be the subject line of an email you’ll receive from us—once we’ve processed your digital order. That email has the link to click, so you can then download the file. This isn't an "instant" process, so if we're asleep, you may need to wait for regular business hours for us to process the order. Although we are quite timely, we may not be processing on weekends & holidays.  Customer Reviews Recently viewed. Our Store is in Brooklin, Maine at 84 Great Cove Drive. We're open Mon-Fri 8am to 4:30 pm Call 1.800.273.7447. WE'RE RIGHT HERE . Timely Shipping We are 99-3/4% sure... that we will ship your order within 24 hours Granted, that does not include weekends and holidays. Secure payments Rest assured... not only is our site secure, we do not hold your credit card/payment info. Opens in a new window. Where We Are Located General FAQs Using this Website Boat Building Methods Boatbuilding FAQs Builders' Forum Login to your account Forgot your password? Forgot your username? Create an account The Principles: Laminating multiple layers of that core (in this case plywood) In alternating directions Forming a monocoque structure (key point) It is for waterproofing as it encapsulates the core, inside and out. It also provides some degree of abrasion  / penetration resistance. Forum Listing Marketplace Advanced Search About The Boat Boat Review Forum SailNet is a forum community dedicated to Sailing enthusiasts. Come join the discussion about sailing, modifications, classifieds, troubleshooting, repairs, reviews, maintenance, and more! Cold-Molded Boats good or bad? Add to quote Welcome aboard. A well built cold molded boat will be light, stiff, and durable. But they were mostly built for racing, and they represent a very small percentage of the market. Glass boats built in the 60's tend to be heavy, therefore solid, and less prone to blisters than 80's boats. But older boats often need much work: new rigging, interior or engine. You really should read this site thoroughly and spend time with sailors and aboard boats before you buy one. Good luck, it's a great lifestyle.   Cold molded boats are great! There are few because they're labor intensive to build.   I believe that Bruce Schwab's "Ocean Planet" has a cold-molded hull. Managed to complete the Vendee Globe in 2005.   For a one-off boat my first choice would be aluminum and my second choice would be cold-molded with epoxy construction. They are in the minority because they don't lend themselves to series production. But they are lighter and stronger than a conventional fiberglass boat. This is where fiberglass wins - one mold and they can pop out hundreds if not thousands affordably. As with any boat you find maintenance is more critical than hull material.   Ocean Planet is cold molded. I sail a cold molded boat, and if ever I was to build a boat. I would use the process. I am very happy with her. You do have to be careful of fresh water, and I have had a couple of small drainage problems. You don't have to be an artist to do a good fix, and the repairs can be easy. Make sure to get a syrveyor who is familiar with the construction....... i2f   Not always, there are different composites....... i2f   A cold molded boat is a boat with a laminated wood or fiberglass hull. The wood is cut into thin strips about 1/8" thick. these are then bent over frames on a diagonal to get the hull shape. Subsequent layers are added with epoxy resin, on the diagonal running the opposite way so they cross. Essentially the hull becomes a single thick piece of plywood. There is a fiberglass material made in strips called C-flex that is also used to build a boat the same way. You don't need a mold, so it is good for a one off. However you don't get a molded smooth gelcoat, so finishing the hull is very labor intensive.   Ah thank you..great info..so its pretty much the same as cold molded then?   In all due respect, there is some confusion here. A cold molded boat can be any combination of wood venners or wood veneers over strip planking. There is no one recipe for a cold molded skin. If you putn a core of foam beween cold molded skins then I would call that a "composite" boat. That is a very good way to build. As for longevity: My cold molded NIGHT RUNNER just won it's class and was First Overall in the Swiftsure Race this weeekend against some very fast and fancy competition. NIGHT RUNNER is 35 yers old!   Thanks Bob, congratulations on the win.   Star: Thank you. I lied. NR is only 32 years old.   I should correct myself. NIGHT RUNNER is only 32 years old. But it has been around Cape Horn and it has plenty of miles on it.   LOL, well, she's practically new! My strip planked ketch (designed by WD Knott) is 43 years old, but I can't imagine she ever won any races. Her design very traditional (enlarged from the 36' gaff schooner Aries). But she's also tight and sound.   Here's a pic of NIGHT RUNNER. Her nickname in Seattle racing circles is THE MAYFLOWER.   Attachments Maestro, You are the client. You have no budget restraints, within reason. What is your choice of hull material ? Don't go all exotic on me. Now Fuzzballl is the client and fuzzball has no budget restraints. I really do like the idea of aluminium but ending up with a hull that looks as pretty as NightRunner would probably sway me to cold moulded.   Wombster: I'd go grp with a foam core. No question.   Interesting Bob. What is your second choice?   I think I have seen the wood one around a bit. Possibly in the woody section at opening day this year. Pretty boat. Not that I have had one, but a foam core hull would be on my top of th elist, if nothing else, altho I could be wrong, but from an insulation stand point, light wt, and there should be no issues with rot like wood. But how I would love to have my little Glen-L 8-ball I built in r high at times......one of these days may I will build another, now there is a S&G version with a dagger board which I would have preferred over the CB version I had..........I digress...... Marty   My second choice would be wood veneers over a foam core. That is a great way to build a strong and light boat if you have the labor skill to do the wood part. JAKATAN, my 41' schooner, was built that way and its a crackerjack boat in everey way.   That's how Rage is built, isn't it? She has proven pretty durable - and fast!   ?             176.4K members Top Contributors this Month 141 IMAGES X 37 Sail Yacht Cold Molded Wood Epoxy Design Andrei Rochian 2014 LA 28: The modern trailable boat that’s cold-molded from mahogany A Herreshoff Coquina X 37 Sail Yacht Cold Molded Wood Epoxy Design Andrei Rochian 2014 Cold molded boat building Details Wooden Boat Finder: 26ft Cold-molded sloop VIDEO Glassing Hull 58 LM46 Whiskey Plank Ceremony at Lyman-Morse Deck Installation at Lyman-Morse 32' Yacht Taraxacus Custom 19 ft Cold Molded Boat Build Video #7 Slow Progress on this Questionable Monohull Project COMMENTS Construction Methods Cold Molded Construction. Cold molded hulls have been built since the technique was used for World War II planes—often using casein or urea-based glues. Today, one would use epoxy almost exclusively, benefiting from its superior bonding, gap-filling, strength and water resistance. ... The pre-cut veneers (2-6 mm thick depending on boat size ... The Advantages (and Fear) of Cold Molding Brooklin Boat Yard has been building cold-molded boats since 1990. That first boat, a 55-footer for then-yard President Steve White, is still racing and looking good, Larkin says. It's evidence that cold-molded boats can be incredibly durable. "We've built 112 boats total," Larkin says. LM46 Performance Cruiser With a low-maintenance, cold-molded hull that offers the unmatched, comfortable motion and ambiance of a wooden boat with the 10-knot-plus speeds of a modern performance yacht, you and your family will form a bond with the LM46 that will last generations. ... Using the cold-molded building process results in a hull that delivers a quiet ride ... Higher Quality, Lower Cost Cold Molded Construction The constraint here is the time available before WEST-system epoxy cures. By keeping the workspace cold (below 50 degrees) and using slow hardener, this meant four hours of working time before the epoxy begins to cure, when the heat is turned up to finalize the cure. But is it possible to apply 240 veneers in four 60-veneer layers, within such ... Boat Building in "Cold Moulded" Boat Building in "Cold Moulded". Moulded Ply or Veneer. This method of construction can be used to build several of our designs, and plans are available based on this technique. From full size patterns supplied with the plans , station frames are marked and cut out of scrap timber and plywood. Stringer positions are marked and notched. Carolina Construction Other builders construct cold-molded boats. The Jarrett Bay difference lies in utilizing the properties of these materials to their very best advantage so that the sum is greater than the whole. Recently Completed. 64' Rebelette. 56' Renegade. 67' Sea Wish. 84' Reel Development. 67' Privateer. LA 28: The modern trailable boat that's cold-molded from mahogany Keel raised: 0.8-1.0m (2ft 8in-3ft 3in) Displacement: 1.5 tonnes. Ballast: 600kg (1,322lb) Engine: Torqeedo Cruise 2.0FP. Price: €120,000 (ex. VAT) The LA 28 is a beautiful, cold-moulded wooden ... Van Dam custom wooden boats & yachts Zoo is a remarkable wooden sailboat constructed in 1982 by Van Dam Custom Boats using the innovative cold-molded boat building process. With meticulous craftsmanship and attention to detail, Zoo embodies the timeless elegance of traditional wooden boat design while boasting modern construction techniques. LM46 Hull No. 2 LM46 Hull No. 2, like every yacht in the LM46 series, is a high-performance, cold-molded sailing yacht that features the comfort and ambience of a wooden boat but delivering 10 knots of speed under both sail and power. The LM46 is a collaboration between Lyman-Morse founder Cabot Lyman, his son and company president Drew Lyman, and top Kiwi ... Wood Boats Sanford Boat Company was established in 1977 to reproduce Nathanael Herreshoff's magnificent Alerion design in modern wood cold-molded construction. We present the result, our ALERION CLASS SLOOP, as the world's finest day-sailor. She has been in our production for 40 years over which time cold molded wood has been accepted as the premier ... Cold-Molded Carolina Boats Cold-molded boats start off upside down and are flipped during the build process. Even as many custom builders embrace Computer Aided Design (CAD), Blackwell prefers to adhere to traditional boatbuilding skills. This builder starts by hand-lofting each vessel, which, in brief, means he makes to-scale drawings of each. Cold Molding the Paine 15 French & Webb and Belmont Boatworks build the hull of the Paine 15 sailboat, designed by Chuck Paine. Video and narration by Chuck Paine. 34' Odyssey: custom cold-molded wooden boat This boat, like our other V-bottom hulls, was built using a stringer/frame system. In this system, transverse frames are erected, in this case on 20" centers. Over the frames go longitudinal stringers. The cold-molded planking goes over the stringers. In the photo, the frames are set up and faired, ready for the stringers. Parker Marine Boat Plans Parker Marine Boat Plans. PARKER MARINE ENTERPRISES sells Construction Manuals, Catalogues, Study Plans and Full Stock Plans. We do custom design work for construction in cold-molded wood, plywood, traditional wood, fiberglass, aluminum, ferrocement and steel. We do on-site or remote consultant work for new construction and major restorations. Van Dam Custom Wooden Boats & Yachts From the cold moulded structure to the electrical and mechanical integrations, we perfect the build process on each custom wooden boat. ... Van Dam Custom Boats are built for generational enjoyment and constructed to stand the test of time. 3D CAD In the design phase we shift from 2D drawings to 3D virtual models, using state-of-the-art 3D ... Build a Boat Carolina 25. The Carolina 25 is a classic North Carolina sport fishing boat design in a trailer-able center console layout. This design features the famous Carolina flare, broken shear and tumblehome that is sure to turn heads. This boat is built using the cold molded method and best suited for those with boat building or woodworking experience. Building with the cold-moulded method Building with the cold-moulded method. After an unfortunate motorbike accident, Harry Evans was forced to put his boating career on hold. However, an opportunity to train as a boatbuilder at the Boat Building Academy in Lyme Regis has given him a fresh start. Here, Harry tells us about his work at the college to build a Clinker sailing boat ... Cold-Molded Boats Posts: 1,178. Cold molding is a master craftsman's artform. It's tough, light and strong (as in the British Mosquito of WWII) but requires exacting care to prevent small voids in the layup. I recall a cold-molded sailboat was built to be dropped from an airplane to let downed pilots sail away to safety. That's tough. The New Cold-Molded Boatbuilding Description. It's generally agreed that cold-molded construction is the best method for the amateur or independant professional interested in building a full-size cruising sail or power boat. A truly appropriate technology, cold molding combines the beauty of wood with the low-maintenance characteristics exceeding those of fiberglass. 15' Cold Molded Catboat--MARSH CAT Cold-molded (four 1/8" layers of mahogany), lightweight and trailerable. LOA - 15' Displ.- 1,309 lbs. Sail Area-152 sq. ft. ... Here's a video on Marsh Cat from our sister publication Small Boats Monthly And, from that Small Boats Monthly feature is this pretty photo of Marsh Cat, taken by builder Kevin McDonald. He built her using strip ... Six River Marine The cold-molded wooden hull is lighter with a more quiet and comfortable ride than its typical fiberglass counterpart. It requires a smaller engine for the same performance. ... a cold-molded boat requires no more annual maintenance than an aluminum or fiberglass boat. The rigid one-piece hull structure provides an excellent base for any paint ... Overview of Cold Mold Construction Forming a monocoque structure (key point) It is called cold-mold because the binder (glue / resin) is designed to fully cure at room temperature. From Wikipedia: Monocoque, from Greek for single (mono) and French for shell (coque), is a construction technique that supports structural load by using an object's external skin as opposed to using ... Cold-Molded Boats good or bad? A cold molded boat is a boat with a laminated wood or fiberglass hull. The wood is cut into thin strips about 1/8" thick. these are then bent over frames on a diagonal to get the hull shape. Subsequent layers are added with epoxy resin, on the diagonal running the opposite way so they cross. Essentially the hull becomes a single thick piece of ... catamaran gulet motorboat powerboat riverboat sailboat trimaran yacht