Building the Mini Sharpie

One of my new years resolutions this year (and last year) was to build a boat. My sister got me two books about boat building for Christmas and I spent a while studying, reading, and planning before finally getting down to business. Although I had originally planned my first boat to be Gavin Atkin’s 12 foot Ella Skiff, I decided to start with something smaller so I wouldn’t have to scarf plywood together on my first build. I ended up basing by boat on the mini sharpie, although I took some liberties to make it more suited to my interests.

For example, I doubled the transom to mount an outboard motor, used a more traditional wire stitch and epoxy glue system, and cut my own corner supports, breast hook, and middle frame. I also bought two sheets of ACX ply because the good stuff wasn’t available in Bethel, and probably wasn’t worth the money for my first boat. I figured by buying two sheets instead of one I could use the best parts of the sheets, and have a little extra wood for the changes I mentioned.

I think the project went pretty well. I learned a ton about working with the materials, what to be careful about in workmanship and what isn’t as critical, and how to be careful. In particular, the warnings you may read about allergic reactions to epoxy are absolutely true. Gloves are not enough. Do not let the stuff get on your skin under any circumstances, and wear a respirator that protects from particulates as well as organic vapors. And don’t sand epoxy that isn’t fully cured. I got really bad rashes up both arms, all over my face and head, and even on my butt. You’ve been warned.

Photos:

One of my two sheets of ACX plywood laid out for marking Side panels cut to size. The second one is traced from the first. This is the 3hp motor I found to use with the boat. A smaller motor would have been ideal. Sides and transom stitched together, and a 2"X2" cross beam giving it some shape. The 2X2 frame is epoxied to the plywood frame and they are epoxied into the hull.

Closeup of how I temporarily nailed the frame into the hull until the epoxy cured. Closeup of the fillet in the bow. After the stitches are removed the fillet will be completed. The bottom is traced, cut, stitched, and filleted. All stitches are removed, fillets are complete, and glass tape for interior fillets are precut. Bow exterior being built up to the proper shape from filled epoxy. You can see the filled stitch holes.

Closeup of a glassed interior fillet. Clearly the work of an amateur. Hull upside down and covered with fiberglass sheet and epoxy. Hull turned back the right way, frame trimmed, and interior sealed Tracing the breasthook from a solo cup.

Corners and breasthook installed with tape rather than stitches and awaiting fillets. Early signs of epoxy reaction. It got much worse. Use your PPE. Taking it out for a first test before installing the motor. Neqa decided to swim along with me.