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Basket Mold Assembly

Basket Mold, A Hull Assembly Method.

The following notes describe our preferred assembly method for small to medium sized sail boats. Other methods such as traditional molds (jig) keel up on strongbacks will produce good results but our basket mold system is easy and fast. It is a proven method used by individual builders and professional boat builders.

Our plans give all the dimensions needed to build with either method. See real pictures on the plans pages for the Serpentaire and the Vagabond.

While a true stitch and glue composite hull can be built without any jig or mold, we preconize the use of a small number of partial female molds. Our plans give all the dimensions necessary for these molds.

The building sequence is outlined below:

• Cut all hull panels from the expanded plates dimensions given on the plans: no lofting is required. Plywood sheets should be assembled with butt blocks before cutting.
• Set up a pair of strong backs, level and block.
• Build the mid frame and set up on the strong.

• Build and set up the two other partial frames.

• Check for squareness, align and brace the molds (bracing is not shown on the drawings).
• Install bottom panel, fasten to the mid frame only with temporary fasteners such as deck screws.

• Install chine panels: align and "stitch" to the bottom panel. Build first layer of fiberglass seam between chine and bottom panel.

• Install topside panel: fasten to mid frame only as much as necessary to keep the panel in position. "Stitch" to chine panel and build seam between topsides and chine, build seam at bow.
• Install transom, build seam around transom.
• Install spacers at deck level and finish all inside longitudinal seams. Fiberglass inside of hull as specified on the plans.
• Install all bulkheads and longitudinal framing, build seams between hull, bulkheads and longitudinal structure. Install floor frames.

• Finish cockpit building.
• Install deck clamp, deck framing.
• Install deck glued on deck framing, no inside seams.
• Build all outside seams easy to reach: deck to hull seam, outside bow and transom seams, topside to chine panels.
• Flip the hull over.
• Build all other outside seams: chine panel to bottom. Fibreglass the outside.
• Build inside hull to deck seams and inside cockpit seams.
• Fair and sand, paint hull with primer.
• Drill holes for keel bolts, CB slot if required.
• Turn hull over.
• Cut deck openings, frame if required.
• Finish inside including CB case if required.
• Fit hull to keel with crane.
• Final paint, rigging, launch!

If you did not find the answer to your question, please use our message board and we will respond within a few hours.
Or explore the HowTo files at our technical support web site bateau2.com