How to Build a Plywood Boat

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Building your own plywood (stitch and glue) boat is a low cost and light weight alternative to spending $10,000+ on an expensive commercially built boat that is difficult to trailer, very heavy, and guzzles gas. Online research, low-cost study plans, and talking to someone who has built their own boat, will help you decide which boat is best for you.

1

Decide which body of water to use your boat on.

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  1. You can’t build a boat that will do everything, so make sure to do your research and narrow down your options. For example, you shouldn’t build a 24' Tolman Alaskan Skiff expecting to use it on a small lake, Midwest river, or pond. On the other hand, taking your 12' rowboat 10 miles (16 km) out in the Gulf of Mexico is probably not the best idea either!
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2

Buy plans from a reputable boat designer.

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  1. Free boat plans on the internet are usually outdated and difficult to read, so try to invest in a modern plan that provides clear instructions and helpful tips. It might not be free, but it will save you money (and headaches) in the long run. [1]
3

Buy quality materials.

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  1. A plywood boat can be beautiful if built, finished, and painted correctly . Using cheap materials will result in poor performance and could be dangerous to your health, depending on which body of water you are using your boat, how far from land you are, and how well you sealed your hull!
    • Use fir, meranti, or okoume plywood. They do not have voids and will not delaminate. It will also use much less epoxy resin as it won't have voids that are common to many cheaper residential construction-grade plywood. [2]
    • Some good brands of epoxy resin include: Aeromarine, System Three, West Marine, and Mas. The boat designer should include the amount of epoxy needed to build the boat design you choose in their plan.
    • Buy a 5–15 gallon (18.9–56.8 L) epoxy resin kit to save money. If you are building a larger boat, you may be able to have your epoxy supplier drop ship your epoxy on a pallet to save you money on shipping.
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4

Learn how to lay fiberglass cloth.

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  1. The truth is 99% of good plywood boat designs are covered in fiberglass. [3] There are dozens of good marine supply stores online that will sell you a quality fiberglass and your boat plans should have the amount (length in yards) and weight (ounces) of cloth you will use on your boat.
5

Give your boat a nice finish.

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  1. Giving your boat a nice finish with marine paint is the key to the longevity of your fiberglass work and the appearance of your boat. Fairing (smoothing and filling your fiberglass cloth grid) and sanding are key to a beautiful show quality finish, but may not be necessary for a work boat in the bayou.
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      Warnings

      • This information is only a quick overview of boat-building and not in-depth Coast Guard approved advice.
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      Things You'll Need

      • Skilsaw w/a good blade
      • 5' orbital sander
      • Belt sander
      • Various knives
      • Scissors
      • Bristle brushes
      • Mixing cups
      • Zip ties
      • Sandpaper
      • Any other items in your boat plans

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      References

      1. ↑ http://www.fao.org/3/y5649e/y5649e00.htm
      2. ↑ https://www.woodenboat.com/marine-plywood
      3. ↑ https://www.youtube.com/watch?v=9jHUI0CiYbs

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