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Assemble the Panels

Cut a First Panel

With the entire outline drawn, we are ready to cut the first side panel.
We use a circular saw with the cut depth adjusted just at the thickness of the panel. This produces a much smoother curve than a jigsaw.

When the first side is cut, we use it as a pattern to draw the second side. Check your nesting drawing for the best layout on the plywood.

The Bottom Panel:

We will use the same method to draw and cut the bottom panel: along lines every 24?, we mark distances, drive nails in those points and draw a nice curve with a PVC batten.
The only difference is that instead of measuring distances from the edge of the plywood we will measure from a centerline.
The plans show the location of that centerline.

Use the same technique as before to draw that centerline: use a plywood panel as a straight edge.

Cut the Bottom Panel.
Now that the pieces for the side and bottom panels are cut, we must assemble them with butt blocks to make long, one piece panels.

Making Long Panels with Butt Blocks:

Long panels are made of several pieces glued together with butt blocks. Butt blocks are pieces of plywood of the same thickness than the panels, epoxy glued. In the case of the FL12, the butt blocks do not cover the whole seam.
Let's start by assembling a side panel.

Note that the layout shows the panels as mirror image: beware not to glue a butt block on the outside of the boat!

Before applying the glue, we recommend to prime the plywood with liquid resin.
When we say resin, we mean a mix of resin and hardener, not just the resin part.
Epoxy resin is always made by mixing two parts, the resin and the hardener.

Epoxy resin is easy to use. The resin looks like a thick varnish. You must mix the two parts, resins and hardener before application. Apply the mixed resin to the plywood or fiberglass and after a few hours, the resin will become hard and strong.
See our separate resin and fiberglass HowTo files for details and experiment with our trial kit.

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