Finally, I've got the deck attached. It took all the epoxy I had left, but fortunately that was enough.
I thickened the epoxy with #2 silica into a very thick paste, and applied it liberally to the deck framing and sheers. As the saying goes, "You never have enough clamps," and I certainly found this to be true once again. I had to get creative with the clamping.
Other than that, it was a pretty straightforward process. The deck is glued on with epoxy only — no screws.
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| These are my two blocks of flotation foam, coated in 2 layers of epoxy and paint. These went in first. |
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| Once the deck panel was on, I used every clamp I had available to bend it to the contours of the framing. |
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| I had to get creative with the clamps. Several of them were daisy-chained together so they'd reach. When I ran out of bar clamps, I had to employ a couple of concrete blocks. |
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| This view shows the forward panel that holds the flotation foam in place. |
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| Clamps removed, and everything seems solid. |
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| Much sanding and finishing remains to be done. |
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| The curves on the ends of the deck panels were meant to cover the gussets on top of frame #2. |
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| Shaping the transom side frame members for the Zip. |
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