How to Shape a Tunnel for a Hull
Boats come in many shapes and sizes. Some boats, such as a catamaran or a speedboat, have a tunnel that runs along the hull of the boat. This tunnel offers more stability and easier handling at high speeds by trapping air beneath the boat. You can create the tunnel shape when building the boat by cutting out the template design on the wood. After building the tunnel, you will stitch and glue the boat together with epoxy and fiberglass.
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Things You'll Need
- Plywood
- Jigsaw tool
- Drill
- Electrical ties
- Duct tape
- 1-by-3-inch boards
- Epoxy
- Filler
- Wire cutters
- Fiberglass tape
- Sander
- 60-grit sandpaper
- Fiberglass fabric
Instructions
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1
Lay out the boat template design on the plywood. Position the template pieces so every piece can be cut out with minimum waste. Outline the template design on the plywood with a pencil.
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2
Cut out the boat pieces with a jigsaw. Connect the plywood together into the shape of the boat by drilling holes along the edges and tying with an electrical ties. Place duct tape to the outside seams of the boat.
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3
Create the tunnel in the hull by making a half-box shape. The tunnel must be at the exact center of the boat, with two equal sides. For example, if the boat is 8 inches across, make the square tunnel 4 inches wide with 2 inches of the regular hull on either side. Use the 1-by-3-inch boards for the tunnel.
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4
Apply epoxy and filler along the inside seams of the boat, avoiding the places with the electrical ties. Press fiberglass tape along the wet epoxy and filler. Allow the epoxy and filler to cure.
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5
Cut the electrical ties with the shears as close as you can to the boat wood. Sand the ties with the sander until the plastic is flush. Dab filler material over the electrical tie ends.
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6
Pull off the duct tape from the bottom of the boat. Seal the outside seams with epoxy, filler and fiberglass tape. Allow the seams to cure.
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7
Place fiberglass fabric over the entire outside hull of the boat, pushing down into the tunnel. Coat the fabric with epoxy. Let it cure.
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