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The downsides of infusion include the possibility of a failure to fully infuse due to a rupture of the bag seal and a resultant loss of vacuum during the process.
They also include the possibility of an insufficiently complete wet-out of the reinforcing material that leaves dry spots in the laminate which must be cut out and patched post-infusion. As well, infusion is generally more expensive than hand lay-up. Although the labor in vacuum infusion might be less, the materials and consumable items associated with the process are relatively quite expensive.
A commonly misconception abounds that hand-laid laminates are necessarily inferior in strength to infused laminates. Which is poppycock.. Provided all other factors are held equal Hand Laid Fiberglass Boat Construction Project � namely, that resins with equivalent post-cure mechanical properties are used in both cases, and very similar types, quantities, and placement of reinforcing materials are employed � a hand-laid laminate will be very close in strength to that of its vacuum infused version.
Whoa, you say, how can that be? Why do so many builders extol the virtues of their vacuum infused laminates? That works well for homogeneous materials such as steel and aluminum. But fiberglass laminate is a composite material made up of glass or other reinforcing fiber encased in a polymer resin matrix. So understanding the comparative strengths of various different laminates is a lot more complicated.
Let me explain. The absolute tensile and bending strengths of an FRP laminate depends almost entirely on the strength, quantity, and type of the contained glass or other fibers and their orientation in the cured final product.
So if two almost identical hulls are laid up, one call it Hull A using hand-lay techniques and the other call it Hull B using vacuum infusion procedures, with identical configurations of fiber reinforcing, hull A will end up with more resin in its cured laminate than hull B.
Consequently, hull A will be not only a bit heavier, but somewhat thicker. But since A has more cross-sectional area because it is thicker than B, the two end up having the same strength when considered on an absolute basis. So then, you ask, what is the big deal and why all the touting of vacuum infusion over hand lay-up? The big deal is that good infused laminates generally achieve the same strength at less weight than an equally good hand lay-up.
And in yachts, you will remember, weight reduction almost always makes a difference to performance and range. The other plus on the infusion side of the ledger is that vacuum infused laminates commonly exhibit more uniformity and predictability than hand-laid laminates, in terms of their post-cured mechanical properties.
And uniformity and predictability are key elements in being able to more accurately engineer the structures built up of those laminates. Read more articles from Phil Friedman:. View Article. A lot of fiberglass deck hatches and cabin tops, for example, are constructed this way.
They appear to be one solid layer, but if cut will reveal an interior core of balsa, foam or plywood.
The combinations of materials provide strength, weight savings, impact and abrasion resistance, and the glass seals the core from moisture. Cores are not a bad thing is used and executed correctly in the design and building of a boat. They tend to be easier damaged by poorly sealed fastener holes - water gets in and can't get out.
The closed-cell foam in a whaler hull tends to be more resistant to water intrusion than say a plywood core on a hatch cover. This is not to be confused by BW's Unibind construction which essentially are two layers separated by a varying distance that creates the shape and varying thickness of the hull and then bonded together with closed cell foam under pressure. I suspect the builders you refer to have a mold that results in a fiberglass hull that resembles lapstrake constructed wood boats.
Lapstrake construction of wood is sort of like siding on a house. To create this profile shape, they probably build up fiberglass in the areas that represent the overlap areas and thereby create ridges of added thickness, sort of like the idea of folding a piece of paper and the seam makes the paper stiff enough to stand up into the air if set on a flat surface.
The closed cell foam core of a BW is not the same thing as a core think sandwich again that makes up a layer of laminates. In the beginning, back in the '50's lapstrake glass boats were fairly common as builders used existing wooden boats for plugs, and many of these plugs were wooden lapstrake boats. There are no stiffeners in the sides of these boats, its only cosmetic. Back in the day, lapstrake wooden boats were common.
You can only do so much, design wise, with plywood, and smooth planked carvel construction means that all the flush seams needed to be caulked. It took very experienced craftsman to build these wooden boats. Then for a short time in the late fifties glass boat builders realized that they were not confined to reproduce traditional boat shapes, and boats began appearing that looked like cars of the day with giant tailfins. I don't know of any boatbuilder today that builds glass lapstrake boats, I guess its a styling thing.
This builder you speak of may have an old lapstrake mold or made one from a wooden lapstrake boat. As far as hand laid, I guess its in the Hand Laid Fiberglass Boat Construction Use translation of the term "hand laid".
It actually means cutting pieces of mat and roving, and laying them in the mold by hand and glassing the pieces in. I mentioned that the method was not hand laid, and the guide said that the chopper gun was operated buy a person. Oh, Hand Laid Fiberglass Boat Construction With well. I liked the boats "look" and recall they made some smallish inboard powered boats with propeller pockets. I can almost sort of remember a 30ish footer they also made. They also stiffen the hull and serve as spray knockers, making the boat pleasantly dry running.
As opposed to using a chopper gun and vacum molding or pressing between molds to consolidate and cure.
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