This technique entails the use of a batten mold for which the full size patterns for each frame are supplied with the construction drawing. Upon building the frame of the mould 1-1/2"x 5/8" battens fairly closely spaced are laid up over them. To this a cheap rigid polyurethane foam, masonite or melamine covered plywood is lain on and the complete outer laminate of the Fibreglass is laid over this former. It is possible that with the battens placed closer together than normal, plastic sheeting can then be stapled over the mould and the fiberglass laminates laid directly onto this. The hull is then turned up the right way and, if foam is used, it is now removed.

In some of the smaller boats it is possible to put channels in the cheap foam and use a modified type of sandwich construction. This only applies in vessels up to 24’. In other cases it may be possible to have enough thickness in the outer skin so that stringers or reinforcements will be unnecessary. Bulkheads, furniture and the floors, will give adequate framing without the addition of ribs or stringers. This construction is generally limited to vessels up to 40’ in length. With the addition of stringers and ribs a vessel of up to 100 feet may be built using this technique.The deck and superstructure can be built using our 'Panel technique' or other fiberglass construction methods.