Replacing the bottom of the Trojan cruiser; by Dave S
by Dave Stabile
(Horseheads, New York (USA))
I replaced a rotten bottom on my 32' double plank cruiser 22 years ago.
The job took me 5 months.
If you plan on such a job like this you only want to do it once.
So I recommend mahogany frames and planking.
I flood coated (epoxy) the frames and epoxy/screwed the planks in place.
Thus far it has worked well and will out last me.
I removed both engines to lighten the hull and then blocked it on the port-side supporting both keel and chine about 2 feet above the ground.
I removed all of the planking on the starboard side saving nothing.
I replaced all of the bad frames, and cleaned up the remaining.
The new frames are 12/4 mahogany.
I used 1/2" marine plywood for the inside layer, and 1/2" mahogany for the outer.
West Epoxy was used on all plank surfaces including the most inner.
So, this ensures a dry bilge and no swelling needed.
After finishing the starboard side I re-blocked the hull on the starboard side and repeated this procedure on the port side.
After finishing this I righted the hull and blocked it.
I used 2 layers of 8oz. fiberglass (52" wide) with West epoxy on the entire bottom.
Next, the rudder and prop shaft holes were bored with a jig I made using a hole saw.
I saturated the holes with West Epoxy.
Re-installed the shafts and engines.
I was very pleased with the outcome.
And of course I had a lot of eyes following this job.
Please, use epoxy resin, not polyester.
And use only marine plywood and Mahogany.