|Babylon Boat Works
We used cardboard to make a template for the transom. Here George is fine tuning it to make it fit perfectly.
The next step is to cut it out of 3/4 marine plywood using a saber saw following the exact template dimensions.
We used the template on a full sheet of plywood and then traced the outline in pencil to make it ready to cut.
This is the finished cut out section. It will then be fit to the transom as closely as possible using a grinder to remove areas of excess wood to make it conform as close a possible to the inner transom dimensions and irregularities in the surrounding fiberglass. When it is fit exactly it then will be used as a template for the second sheet of marine plywood as the transom requires 1 1/2 inches of inner marine plywood core. These two sheets of plywood will then be hot coated with resin and be mated one at a time to the inner skin and then the second mated to the first sheet to form the core. It will all then be glassed in using the cut out piece of outer fiberglass skin and totally glassed in with strong bi-axial and matte fiberglass.
George is cutting away saturated core from the aft deck using a Fein tool. Small pieces of 1/2 inch marine plywood will then be fit in this area.
A cardboard template is made for the missing rear deck section.
The template was used to cut the plywood for the rear deck and with a grinder, fit into place. This will then be hot coated with resin and then glassed into place. This area will also be braced underneath for added strength using the stringers for support. The entire area under this deck will then be filled with 4 pound expanding foam.