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.

My procedure:

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.

Dave S.