Zip Boat DIY

A ZIP boat is a small, general-use boat that is designed by Glen L Marine Designs to be built by beginner boat builders. The ZIP measures 14 feet from stem to stern, has a wide, flat bottom that enhances stability and can be equipped with a motor. Glen L provides the plans for building the ZIP, and customers purchase the materials to build the boat. The ZIP is a good starting point for beginning boat builders because the method for putting the pieces together involves simple-to-use tools and uses common materials.

Things You'll Need

  • Boat plans
  • 1/4-inch marine plywood
  • Marker
  • Transfer paper
  • Reciprocating saw
  • Power drill
  • 1/4-inch screws
  • Power sander
  • Power screw driver
  • Epoxy glue
  • Fiberglass resin
  • Fiberglass cloth
  • Spatula
  • Paint brush
  • Paint or varnish
  • Sandpaper
  • Safety glasses
  • Dust mask
  • Gloves
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Instructions

    • 1

      Acquire the plans to build your boat. The plans are the most crucial element in the building process because once you have the plans, you have the foundation on which to build your boat. Plans may be purchased new online or used from boat builders who have already built their own ZIP.

    • 2

      Trace the outline of the various sections of your boat onto the marine plywood using a marker, transfer paper and the plans that you acquired.

    • 3

      Cut the sections out of the plywood using a reciprocating saw. Sand all the edges of the plywood to eliminate any shards of wood or rough edges. Sanding the joints is an important step because the epoxy needs to form a proper bond.

    • 4

      Drill 1/4-inch holes in the joints that are to be glued together. The boat plans will indicate where these holes are to be drilled. Attach the pieces of the boat together using 1/4-inch screws.

    • 5

      Apply epoxy to all the interior seams of the boat using a spatula. Apply the epoxy generously to the seams so that the bottom and sides of the boat are consistently connected. Finish the interior by gluing the cross braces and the seat to the middle of the boat.

    • 6

      Apply epoxy to all exterior seams of the boat. Allow the epoxy to dry and cure according to the manufacturer's instructions before continuing any work on your boat.

    • 7

      Cover all interior and exterior seams with strips of fiberglass cloth that have been saturated with epoxy. Allow the seams to dry and cure.

    • 8

      Cut a piece of fiberglass cloth that is the size of one of the exterior panels of your boat. Use a paint brush to cover this panel generously with fiberglass resin. Apply the cut piece of fiberglass cloth to this panel. Repeat this process for all remaining exterior sections of your boat, overlapping the edges of the fiberglass cloth over the seams. Apply a final coat of resin over the cloth and allow it to dry and cure. Repeat this step for the interior of your boat.

    • 9

      Sand your boat so that it has a smooth finish. Finish the boat with at least two coats of paint and polyurethane. Inspect the boat for any imperfections and correct them before applying the final coat of polyurethane. Allow the paint and polyurethane to dry between coats.

    • 10

      Attach any necessary marine hardware to your boat, including a motor, oars, cleats or tie rope. Test your boat to check for leaks. Fix any leaks immediately with epoxy.