Construction & Materials
Thousands of people find that they love building a boat. This process is so clean it can even be done in an apartment.
What is Geodesic Airolite Construction? It is a simple, inexpensive, low-tech, forgiving system utilizing some exotic materials. The sequence consists of building a simple rugged wood framework braced with triangulated KEVLAR® roving strands (very thin, flat, stranded twine). This tough basket-like frame is then covered with 600D polyester, similar to sail cloth; except it heat shrinks. It is a lightweight, airplane wing covering type of fabric, similar to that used on crop dusters.
Obviously, polyester covered boats are not bulletproof...they must be treated with some respect, but not pampered. This is a tough, resilient material that will take quite a beating from rocks and snags; however, it cuts fairly easily with a sharp object like a broken bottle. This has proven to be no problem. Carry some duct tape and DON'T WORRY! You can easily make a permanent repair at home. There is little reason for repairs; instead of dragging your boat over barnacle-studded rocks, you simply pick it up (with one or two fingers) and carry it out of harm's way. There are many stories about how these boats have survived abuse due to the resilience of the framework. Many builders are just now re-covering boats that were built over 20 years ago.
The construction technique is fun and educational, requiring only simple tools and limited space. There are many advantages for the home builder. The materials are inexpensive and there is no need for elaborate forms, lofting, spiling, planking, sanding and fairing epoxy, etc. associated with other boat building methods. There are no messy operations involved.
Plans include: A comprehensive instruction manual with full size patterns, which are transferred to the station molds. Thin plywood is most often used but some builders have used heavy corrugate. These are set up on a lightweight box beam strong back. There are many ways to build a strongback using materials you may already have around the shop. A lightweight but useable strongback can be made with 1x6 boards top and bottom with corrugated sides. The strongback and station mold assembly is portable, facilitating a number of boats being built in living rooms.
A first-time builder can complete the simpler designs in 3-4 weeks of spare time. You will be fascinated to learn new techniques like heat shrinking and steam bending. In fact, most builders are very anxious about those two steps but end up enjoying them the most! The steps are well described and easy to master and our YouTube channel has over 25 helpful videos.
A number of highly successful school projects show that the process isn't too difficult. Platt took special pride in these school projects and many of them are still going on today.
Our YouTube channel (mentioned above) shows all of the steps needed to build a frame, cover the frame and shrink the polyester. We don't cover painting or varnishing because there are simply too many products to test. Our favorites are included in the Finishing the Hull video (link).
To build a partial kit you will need: Access to a table saw equipped with a good sharp thin kerf blade. You can use a standard blade but will waste a lot of wood cutting the thin strips. A good money saving tip: use a 7 1/4" thin kerf blade on your 10" table saw. The smaller blade is about 1/4 the cost of a 10" thin kerf blade. A supply of clear, straight, tight grain wood will be needed. Unfortunately, the dimensional lumber in the "stacks" at most big box lumber stores has a very loose grain and is not suitable. Luckily, these same stores offer their premium woods, usually red oak, poplar, spruce and cedar, that works extremely well for our boats. If you have small knots, cut between them and do some scarfing. See our YouTube video on Making a Scarf Joint (link)