Hi Folks,
Spindrift 11N #1683 checking in from Europe. Started build in March from 5 sheets of 4mm ply.
Highlights:
- Laser rig (not yet fully fitted)
- 4mm ply + glass
- very lightweight
- forward seats
- great & cheap fenders.
- easy nesting bolts
Photos and finished weight (I keep forgetting!) to follow.
I wrote a bunch of tips during construction but lost (!) them during the transition to full-time liveaboard. Did my best to put them together today. They are long and rambling and available HERE Then I asked GPT to edit them and fixed that up - much more digestible and pasted below. Sorry for the bold type, view at the link if you prefer.
I prioritized light hull weight above pretty much everything. I also wanted to gain composites experience.
Many many thanks to everyone who contributed build logs/tips/videos here and elsewhere. Couldn't have done it without you.
Construction
Materials:
Marine Plywood: 4mm marine ply
Fiberglass:
200, 150, or 100gsm 2x2 twill glass everywhere except inside the aft seats, depending on requirements
10cm 300gsm 45x45 glass tape inside as per plans
300gsm tape on/over keel and strakes
14mm aramid flat braid + 300gsm 45x45 tape on keel and strakes
Inside bow keel much reinforced
Parts
Knees, transom, keel/strakes, breasthook: Spruce
Seat cleats and gunwales: Pine/fir
Mast Step: Marine ply, 300gsm bearing plate
Foredeck: Skeletonized 4x4mm marine ply, 200gsm glass both sides
Mast Step Turning Block Plate: ~6 layers of 600gsm built over a simple mold to make the angle
Rowlocks: Meranti with 316 stainless steel pipe epoxied inside, epoxied on and screwed into the gunwales
Assembly:
Tape as per plans, no tape outside except keel and strakes (see regrets)
Aft floor stiffened with strakes parallel to keel
No plywood cap on the inner transom (200gsm glass both sides)
Nesting bulkheads thinned and glassed
Cleats are minimal (e.g., 21x21 triangular section pine), relying on the glass and lightweight users
Fastening
Screws:
316 wood screws, minimal use, only for breasthooks, rowlocks, and knees
Nesting Bolts:
Used 5x M6 eye bolts:
Top two backed by M6 eye nuts for ample torque
Lower three greased bolts potted with nut + washer in thickened epoxy within plastic bottle caps
Each bolt fitted with a large M6 washer and ~5mm O-ring to prevent leaks and keep washer captive
All bolts can be threaded together as a bundle for storage (inside a seat)
Misc
Ties:
Regular galvanized steel wire preferred over zip ties for better control and smaller holes
Rigging:
No padeyes; everything is potted holes with 2-6mm Dyneema threaded through
2mm padeyes in all four corners of the NBKHDs for 3/4 point lifting if needed
Knee eyes double as traveler (whoopie sling with LFR)
Whoopie tail has an eye splice looped over the outboard screw as the safety line
Incident
Accidentally dropped the plane in the bow during assembly and smashed it open along keel
Recovered using a Spanish windlass with no harm done
Specific Components
Gunwales:
Hardest part to machine
Required creative use of track saw and jury-rigged router table for angles
Lap joints worked fine, not the hard part
A router table and table saw would expedite the process
Foredeck:
Sloped forwards to drain water through the painter (6mm dyneema) hole
Cleated around three sides, relying on 16mm thick plywood + glass for strength and stiffness
Foredeck hatch for anchor and bailer storage
False floor, sloped aft, with a drain bung
Floor serves three purposes:
Collision protection
Easily drain water/rinse out anchor mud
Protect the hull in case the anchor is dropped
Fenders:
~10mm rectangular rubber around the outside of the gunwales
Firehose cut lengthwise in half, contact cemented in place
Hit hard with a plastic mallet and use high-quality cement (~300g used)
Wedges for Nesting:
Forward piece slightly smaller than the aft piece to allow sliding on deck
Fixed two wedges on the inside corners of the aft nesting bulkhead to prevent damage
Foredeck and Seating:
No midships seat; daggerboard trunk just wide enough for seating
Rowlocks ~14.5 inches aft of the seat edge
Potential to add seats or carry gear/passengers in the back
Epoxy Tips
Resources:
Explorecomposites (site) and Easycomposites (youtube) for good insights
Application:
Wash all epoxy before sanding unless peel ply was used
Use peel-ply on areas that are not tortured nor have sharp radii
Cut green epoxy with a razor blade instead of waiting until it dries
Mixing Fillers:
Mix cotton flocks with silica and/or microballoons to minimise dust (AMAZING!)
Glue: 1 silica : 2 cotton @ <15% w/w
Fillets and Filler: 25 microballoons : 5 silica (optional, to prevent runs) : 5 cotton @ <30% w/w
Fillers are economical, reduce weight, and dramatically decrease resin usage ($$$)
Pigments:
Use pigments in resin for easier identification of drips, new glass, and mixed resin
Example: Purple for glue, white for fillets, green/blue/yellow for resin
Fillet Application:
Use freezer bags instead of icing bags:
Place a 200ml paper cup inside a freezer bag
Add fillers by weight and a drop of pigment
Mix resin in a separate 100ml cup for reuse
Add resin to the bag, close and knot with minimal airspace, knead together, and nip a corner for a perfect fillet bag
Silicone spatula set preferred over sticks for fillets
Additional Tips:
Clean with acetone after using debulking rollers; store acetone in a large HDPE container with an airtight lid
Invest €40 in a proper respirator and store it in a gallon ziplock when not in use
Dry used cups and mixing sticks on peel ply for reuse
Poor Man's Prepreg:
Use lightweight painter’s plastic (e.g., Tesa with masking tape on one side)
Lay out larger sheets than the glass size
Dribble resin on glass, add another plastic sheet on top
Use a plastic squeegee with masking tape to wet out the glass completely
For complex layups, use slow resin and freeze sheets before cutting
Reference: DIY Prepreg Video
Use slip joints on inside corners, esp if vacuum bagging
Apply a little thickened epoxy to outside corners before glassing to prevent voids
Avoid using 3x epoxy; use 100gsm glass for faster, neater, stiffer results with the same weight
Best Tools
Dust collection! I used a karcher shopvac
Shinto rasp (I feel like a sinner but it's great)
Router with roundover, pattern, and plunge bits
Track saw (table saw preferred if space allows) for cutting plywood
Lofted, cut, and built on OSB sheets with IKEA sawhorses, hot-glued, screwed, and levelled in place
Permagrit block
Jack plane (consider adding a block plane)
Pull saw
150mm sander with soft pad, Abranet discs (pay for themselves)
Oscillating multitool with Permagrit (tile/carbide) blade for glass
Jigsaw
Hole saws
Good cordless drill
Makita 9031 band file
Angle grinder (if space allows for making a big mess)
Performance and Usage
Steering and Control:
Bangkirai outboard pads fit a Suzuki DT2.2 perfectly, compatible with standard Laser rudder gudgeons
Minor binding due to Laser transom rake, not problematic
Laser rudder+head+gudgeons
Speed:
7 knots in flatish water with 2.2hp motor, two people (110kgs), and minimal gear
5.5 knots at half throttle
Dryness and Handling:
Pretty dry even in good chop; gunwales and flare perform well
Slightly increased forward freeboard from plans
Plans Feedback
Keel Lines:
Difficulty fairing keel lines at the bow on metric plans
Ended up using imperial plan measurements, not realising stations were different, resulting in a shallower forefoot than intended
Required some trimming on FDK and FBKHD
Aft Seat Sections:
Metric plan lines for aft seat vertical sections confusing regarding inside vs. outside ply edges where they meet the hull
Dimensions:
Single dimension per point in main plans; extra dimensions for alignment/checking would save a lot of tears.
Gunwales:
Within reach for average builder but probably require two people and create a mess
Suggest simplifying assembly procedure if possible
If I did it again, would do one layer at a time and use mostly screws + ply pads
Forward Seats:
Recommend adding forward seats to plans for easier construction
DIY with a joggle board and level was awful
Critical for enough floatation/collision protection when sailing/motoring in open waters without support
Inspired by other posters' pictures and much indebted
Future Projects
Oar Rack:
Ocean South heavy-duty 215mm aluminium 2-part, fits perfectly alongside forward seats and rudder
Stern Seat:
Tricky to row with someone on one side; ideal to have a drop-in seat well forward
Daggerboard Trunk Cap:
Gasket using sealant + plastic wrap release film
Essential for sealing
Rig:
Currently have a full Laser rig lashed to the toerail in a bag
Scored a Laser rig, rudder, sail, and board for €200
Plans to chop the bottom off the mast sleeve and add halyard and clew webbing eye for reefing
Regrets
Daggerboard Trunk:
Should have fully boxed the trunk for alignment during assembly
Protrusion on aft piece and vertical slot in trunk/NBKHD like the Chameleon
Neodymium magnets were ineffective
Foredeck Reinforcement:
Should have used more glass on the foredeck (e.g., 2x200gsm, 10mm foam, 4mm ply, 3x200gsm)
Foredeck gets abused when living on deck
Foam Usage:
Should have used more foam or foam + plywood in areas like foredeck, seats, and bulkheads
Keel Extension:
Should have extended the keel or Kevlar tape further forward to prevent damage, forefoot gets abused
Bolt Strength:
If lower, center bolt was stronger, could have used the eye to fix a mainsheet turning block
Considering adding a second bolt or padeye with more substantial reinforcement
Additional Glassing:
More glass needed in high-abuse areas: NBKHD upper corners, top of gunwales, aft seat edges, forefoot of keel, foredeck
300gsm tape sufficient, but open weave adds unnecessary epoxy weight
Paint:
2-pack paint was too stinky, difficult to work with, and slow to drycompletely
Recommend using 1-pack paint with a common color (e.g., 9003) for easier matching and repairs
Prefer painting just the outside before leaving on our trip for easier repairs and reinforcements
Workspace:
Built 80% in a spare bedroom and laundry
Asked boatyard to rent space in shed: "sure, no charge" - would have been way faster earlier.
Climate-controlled space is critical, especially when working with epoxy
Alternative Designs
Chameleon:
Small, overbuilt, insufficient freeboard
Pt11:
Expensive, no plans, elegant nesting, kit not shipping to EU
Fb11:
Pram bow, no enclosed seats, limited information
Stasha Skin on Frame:
Not suitable for foredeck abuse, tough to clean
Mebo 12:
Mebo 12 Design
Very close to our design goals, few built, possibly too big for some decks
Goat Island Skiff:
Not nesting
OK Dinghy:
Nice lines
Cherub:
Good for design/construction inspiration.
Closing Thoughts
Overall Experience:
Fantastic boat; highly satisfying to build and use a great dinghy
First day motoring around to a sunny beach was magical
Cost and Time:
More expensive and time-consuming than anticipated
Choice of glass + vacuum bagging increased complexity and duration
Experienced builders could complete faster
Timeline: Started in March, launched painted in July while refitting the big boat
Construction Insights:
4mm ply + glass is doable and lighter, but requires good understanding of forces, stiffness, and strength
Necessary to calculate/test Young’s Modulus for different orientations and weights
Not cheaper or easier without proper knowledge or designer assistance