How to Pull Epoxy Fillets

This is the fifth video in the FRS12 how to build a boat series where we build a plywood boat. We cover how to pull epoxy fillets. This shows how the frames are epoxied to the hull with epoxy fillets and the individual plywood pieces become one large piece. This is where a boat is born! These plywood boat plans and more are available for purchase, and come with full size patterns.

We’ve mixed thickened epoxy and spread it out on the board, because it’s so hot, so it doesn’t cure in the cup. We will pull fillets in between the zip ties. That will hold our boat together, and then we’ll cut out the zip ties.

Once the fillets are pulled (but not cured) we use a putty knife to clean up all the epoxy that pushed out the side and smear it on the board to reuse it.

We pulled the fillets and cleaned it up. Now we’re going to let it cure and cut our zip ties. Then we’ll pull the fillets in between. But first we’re going to pull the fillets in the whole boat, all the way to the front.

All the fillets are pulled, and we’ve cut all the zip ties out, expect for those holding the bottom to the chine.

After You Pull Epoxy Fillets

We supported the keel all the way down the center with a straight 2×4. Then we covered it in plastic (or tape) so the epoxy doesn’t drip down and bond the 2×4 to the boat.

Now we’ve mixed up some thickened epoxy, got a spreader and are going to use the flat side. We’ll use a little pressure as we pull to shove it into any cracks or holes.

We’ve applied just enough pressure so that we’ve pushed the epoxy down into the crack of the wood. This fills the holes, but we haven’t applied too much pressure that we’ve bent it into a full curve. So there is epoxy built up above the plywood. That’s what your glass will lay on. And we’re going to do that all the way from the front bulkhead to the transom.

Let the Epoxy Cure

So after we cut our zip ties and applied our thickened epoxy, our plywood wanted to lift and relax a little bit, not staying in contact with the 2×4 underneath. To ensure we keep a straight keel, we apply a little bit a weight at the keel from what ever we had around the garage, which keeps our bottom on the 2×4 and keeps our bottom straight.

You can build your own boat using our plans and instructional how to videos!