FRS 16 Hull Build: Project Plan

Project: Scoughxxuene 2.0 Hull Build Student: John Hurff Semester: Fall 2026 Build Window: August 6 – December 10, 2026 Shop Day: Thursday, 8:00 AM – 12:00 PM

Phase Milestones

Phase Sessions Thursdays Target Completion Status
1: Setup & Planning 1–3 Aug 6, 13, 20 August 20, 2026 Pending
2: Stitching 4–6 Aug 27 – Sep 10 September 10, 2026 Pending
3: Framing & Epoxy Seams 7–9 Sep 17 – Oct 1 October 1, 2026 Pending
4: Epoxy Sealing & Fiberglass 10–12 Oct 8–22 October 22, 2026 Pending
5: Custom Build-Out 13–15 Oct 29 – Nov 12 November 12, 2026 Pending
6: Finishing 16–18 Nov 19 – Dec 10 December 10, 2026 Pending
Final Report — — December 10, 2026 Pending

Class Schedule

18 shop sessions on Thursdays, 8:00 AM – 12:00 PM. Thanksgiving week (November 26) is skipped.

Quick Reference

Session Date Phase Focus
1 Thu, Aug 6 Phase 1 Course Kickoff & Safety Orientation
2 Thu, Aug 13 Phase 1 Kit Inventory & Verification
3 Thu, Aug 20 Phase 1 Customization Design & Material Planning ✓
4 Thu, Aug 27 Phase 2 Hull Panel Dry Fit
5 Thu, Sep 3 Phase 2 Stitching — Hull Bottom & Sides
6 Thu, Sep 10 Phase 2 Stitching — Transom, Bow & Completion ✓
7 Thu, Sep 17 Phase 3 Frame & Bulkhead Installation
8 Thu, Sep 24 Phase 3 Thickened Epoxy — Interior Seams
9 Thu, Oct 1 Phase 3 Thickened Epoxy — Exterior Seams & Keel ✓
10 Thu, Oct 8 Phase 4 Epoxy Seal — All Interior Surfaces
11 Thu, Oct 15 Phase 4 Fiberglass Cloth — Interior
12 Thu, Oct 22 Phase 4 Fiberglass Cloth — Exterior & Hull Bottom ✓
13 Thu, Oct 29 Phase 5 Storage Compartments & Livewell Rough-In
14 Thu, Nov 5 Phase 5 Casting Deck & Flooring
15 Thu, Nov 12 Phase 5 Rod Holders, Accessory Mounts & Hardware ✓
16 Thu, Nov 19 Phase 6 Sanding, Fairing & Paint Prep
— Thu, Nov 26 — THANKSGIVING BREAK — No Session
17 Thu, Dec 3 Phase 6 Primer Application
18 Thu, Dec 10 Phase 6 Final Paint (USA Theme) & Hull Completion ✓

✓ = Phase checkpoint session

Week-by-Week Schedule

Session 1 — Thursday, August 6

Phase 1: Setup & Planning Focus: Course Kickoff & Safety Orientation

Accomplish this session:

  • [ ] Review course overview, SMART goal, and semester schedule with Jimmy

  • [ ] Conduct full shop safety orientation — PPE, epoxy and solvent handling, power tool safety, ventilation

  • [ ] Set up workbenches and tool stations in the garage

  • [ ] Organize chemical storage (epoxy, solvents, primers)

  • [ ] Walk through the FRS 16 build plans together — identify all major sections

  • [ ] Complete and sign shop safety checklist

  • [ ] Document workspace setup with photos

  • [ ] Write Journal Entry 1

Session 2 — Thursday, August 13

Phase 1: Setup & Planning Focus: Kit Inventory & Verification

Accomplish this session:

  • [ ] Unpack all CNC-cut panels and lay them out

  • [ ] Cross-reference every panel against the build plans and parts list

  • [ ] Label each panel with chalk or painter's tape (panel name and orientation)

  • [ ] Photograph every panel (guest photo catalog task)

  • [ ] Inventory all supplemental materials — foam, hardware, plans, HIN documentation

  • [ ] Note and document any missing or damaged components

  • [ ] Write Journal Entry 2

By end of session: Every kit component identified, labeled, and photographed.

Session 3 — Thursday, August 20

Phase 1: Setup & Planning Focus: Customization Design & Material Planning Phase 1 Checkpoint

Accomplish this session:

  • [ ] Finalize customization design — storage compartment locations, livewell size and placement, casting deck dimensions, rod holder positions

  • [ ] Produce interior layout design sketch with all custom features marked

  • [ ] Research and select USA-made materials and hardware for all categories

  • [ ] Complete full material procurement list with sources and USA-made designations

  • [ ] Place orders for all long-lead materials — epoxy, fiberglass cloth, foam (if not in kit), paint, rod holders, livewell hardware

  • [ ] Verify all materials will arrive before Session 5 (stitching begins)

  • [ ] Write Journal Entry 3

Phase 1 Complete when: All panels labeled and inventoried; design sketch finalized; all materials ordered or confirmed on hand.

Session 4 — Thursday, August 27

Phase 2: Stitching Focus: Hull Panel Dry Fit

Accomplish this session:

  • [ ] Set up building supports and sawhorses on the shop floor

  • [ ] Begin fitting hull bottom panels — no stitching yet, dry fit only

  • [ ] Fit port and starboard side panels against the hull bottom

  • [ ] Check panel alignment and hull symmetry from bow to stern

  • [ ] Verify rocker (the curve of the hull bottom from bow to stern)

  • [ ] Mark all stitch points along every seam — every 6 to 8 inches

  • [ ] Write Journal Entry 4

By end of session: All panels dry-fit in correct position; stitch points marked on all seams.

Session 5 — Thursday, September 3

Phase 2: Stitching Focus: Stitching — Hull Bottom & Sides

Accomplish this session:

  • [ ] Drill stitch holes at all marked points along hull bottom and side seams

  • [ ] Stitch hull bottom panels together at centerline with zip ties

  • [ ] Stitch port side panel to hull bottom

  • [ ] Stitch starboard side panel to hull bottom

  • [ ] Check and adjust hull shape as stitching progresses — tension zip ties to achieve correct form

  • [ ] Write Journal Entry 5

By end of session: Hull bottom stitched at centerline; both sides stitched to bottom; hull beginning to take shape.

Session 6 — Thursday, September 10

Phase 2: Stitching Focus: Stitching — Transom, Bow & Completion Phase 2 Checkpoint

Accomplish this session:

  • [ ] Stitch transom panel to hull bottom and sides

  • [ ] Stitch bow panel into position

  • [ ] Stitch any remaining structural panels — spray rails, chine panels per plans

  • [ ] Verify symmetry: measure beam width at bow, mid-ship, and stern — port and starboard must match

  • [ ] Record beam measurements in journal

  • [ ] Trim all zip tie tails flush

  • [ ] Write Journal Entry 6

Phase 2 Complete when: Hull fully stitched; all panels in final position; beam symmetric at all three measurement stations.

Session 7 — Thursday, September 17

Phase 3: Framing & Epoxy Seams Focus: Frame & Bulkhead Installation

Accomplish this session:

  • [ ] Review frame locations in build plans before cutting or fitting anything

  • [ ] Fit Frame 1 — trim as needed for a clean fit against hull panels

  • [ ] Check Frame 1 for plumb (vertical) and correct position fore/aft

  • [ ] Temporarily secure Frame 1 with clamps or zip ties

  • [ ] Repeat for all remaining frames and bulkheads

  • [ ] Verify frame spacing matches plans after all frames are in

  • [ ] Mark fillet locations at all frame-to-hull joints

  • [ ] Write Journal Entry 7

By end of session: All frames and bulkheads fitted, positioned, and temporarily secured.

Session 8 — Thursday, September 24

Phase 3: Framing & Epoxy Seams Focus: Thickened Epoxy — Interior Seams & Fillets

Accomplish this session:

  • [ ] Mix first batch of thickened epoxy — record ratio, temperature, and pot life in log

  • [ ] Apply epoxy fillets to interior panel seams working systematically bow to stern

  • [ ] Apply epoxy fillets at all frame-to-hull-bottom joints

  • [ ] Apply epoxy fillets at all frame-to-hull-side joints

  • [ ] Smooth all fillets to a consistent radius using a radius tool or gloved finger

  • [ ] Allow to cure per manufacturer specifications before disturbing

  • [ ] Log all epoxy batches mixed this session

  • [ ] Write Journal Entry 8

By end of session: All interior panel seams and frame joints filleted.

Session 9 — Thursday, October 1

Phase 3: Framing & Epoxy Seams Focus: Thickened Epoxy — Exterior Seams & Keel Phase 3 Checkpoint

Accomplish this session:

  • [ ] Access or flip hull to work on exterior seams

  • [ ] Mix thickened epoxy and apply fillets to all exterior chine seams (where bottom meets sides)

  • [ ] Apply keel fillet — a continuous, generous bead running the full length of the hull bottom centerline

  • [ ] Feather and smooth all exterior fillets

  • [ ] Inspect all interior fillets from Session 8 — fill any voids or thin spots

  • [ ] Log all epoxy batches mixed this session

  • [ ] Write Journal Entry 9

Phase 3 Complete when: All interior and exterior seams filleted; all frame joints bonded; no voids or gaps; keel fillet full length.

Session 10 — Thursday, October 8

Phase 4: Epoxy Sealing & Fiberglass Focus: Epoxy Seal — All Interior Surfaces

Accomplish this session:

  • [ ] Mix neat (unfilled) epoxy per manufacturer instructions

  • [ ] Apply first seal coat to all interior surfaces — use rollers on flat areas, brushes in corners and tight spots

  • [ ] Work section by section to avoid missing any areas

  • [ ] Apply second coat before first coat fully cures (green stage) for maximum penetration

  • [ ] Inspect for any dry spots or fisheyes; re-coat as needed

  • [ ] Pre-cut fiberglass cloth panels for Session 11 while epoxy cures

  • [ ] Write Journal Entry 10

By end of session: All interior surfaces sealed with minimum two coats; fiberglass cloth pre-cut for interior application.

Session 11 — Thursday, October 15

Phase 4: Epoxy Sealing & Fiberglass Focus: Fiberglass Cloth — Interior Application

Accomplish this session:

  • [ ] Dry-fit all pre-cut interior fiberglass cloth pieces before mixing any epoxy

  • [ ] Wet out and apply fiberglass cloth to hull bottom interior

  • [ ] Wet out and apply fiberglass cloth to bilge and keel area

  • [ ] Wet out and apply fiberglass cloth to transom interior

  • [ ] Roll out air bubbles from each section — glass should be fully translucent when properly wetted

  • [ ] Trim excess cloth at edges while still wet

  • [ ] Write Journal Entry 11

By end of session: All required interior areas glassed; no dry spots (white areas) visible in cured layup.

Session 12 — Thursday, October 22

Phase 4: Epoxy Sealing & Fiberglass Focus: Fiberglass Cloth — Exterior & Hull Bottom Phase 4 Checkpoint

Accomplish this session:

  • [ ] Inspect and lightly sand interior glass work from Session 11 — knock down any high spots or ridges

  • [ ] Apply fiberglass cloth to hull bottom exterior — full coverage from chine to chine

  • [ ] Apply fiberglass tape over all exterior chine seams (both port and starboard)

  • [ ] Apply fiberglass cloth to transom exterior

  • [ ] Allow full cure before Phase 5 begins

  • [ ] Sand any rough glass edges once cured

  • [ ] Write Journal Entry 12

Phase 4 Complete when: All interior and exterior areas glassed; no dry spots; cured glass is solid and firmly bonded; hull is structurally complete.

Session 13 — Thursday, October 29

Phase 5: Custom Build-Out Focus: Storage Compartments & Livewell Rough-In

Accomplish this session:

  • [ ] Transfer interior layout design sketch to the actual hull — mark all compartment walls and livewell location with pencil or chalk

  • [ ] Cut interior divider walls for storage compartments to fit

  • [ ] Dry-fit all dividers; trim as needed

  • [ ] Epoxy-bond storage compartment dividers into position

  • [ ] Cut livewell opening to planned dimensions

  • [ ] Fit livewell liner or box into opening

  • [ ] Mark livewell drain and supply plumbing locations

  • [ ] Apply epoxy seal coat to all new wood surfaces in storage and livewell areas

  • [ ] Write Journal Entry 13

By end of session: Storage compartment structures installed; livewell roughed in with liner fitted and plumbing locations marked.

Session 14 — Thursday, November 5

Phase 5: Custom Build-Out Focus: Casting Deck & Flooring

Accomplish this session:

  • [ ] Cut casting deck panel(s) to fit the bow section — work incrementally, test-fitting often

  • [ ] Install deck support cleats along hull sides and forward frame

  • [ ] Dry-fit casting deck; verify fit and verify it sits level

  • [ ] Epoxy-bond casting deck into final position

  • [ ] Apply fiberglass cloth over casting deck surface for durability and sealing

  • [ ] Install any other deck flooring sections per design

  • [ ] Apply epoxy seal to all new wood

  • [ ] Write Journal Entry 14

By end of session: Casting deck installed, bonded, and glassed; all flooring sections complete.

Session 15 — Thursday, November 12

Phase 5: Custom Build-Out Focus: Rod Holders, Accessory Mounts & Hardware Phase 5 Checkpoint

Accomplish this session:

  • [ ] Mark all rod holder positions on hull sides and gunwales

  • [ ] Drill rod holder holes; install backing plates with wood doublers behind each

  • [ ] Install rod holder tubes and secure

  • [ ] Fabricate and install Power-Pole mounting bracket at transom — reinforce backing

  • [ ] Install trolling motor bow mount backer plate at bow

  • [ ] Mark jack plate mounting location on transom; apply wood doubler and glass reinforcement

  • [ ] Verify all USA-made hardware is on hand; document sourcing for each item

  • [ ] Write Journal Entry 15

Phase 5 Complete when: All storage, livewell, casting deck, rod holders, and accessory mount locations are installed, reinforced, and sealed.

Session 16 — Thursday, November 19

Phase 6: Finishing Focus: Sanding, Fairing & Paint Prep

Accomplish this session:

  • [ ] Inspect the full hull exterior — look at low angle against the light to spot high spots, ridges, and low areas

  • [ ] Apply epoxy fairing compound to any voids or low spots; allow to cure

  • [ ] Block sand full hull exterior — 80-grit first pass to knock down high spots

  • [ ] Block sand — 120-grit second pass

  • [ ] Block sand — 180-grit final pass for paint-ready surface

  • [ ] Hand sand edges, corners, chines, and any areas block can't reach

  • [ ] Wash hull with clean water; allow to fully dry

  • [ ] Tape off transom area, hardware mounts, and any areas not to be primed

  • [ ] Write Journal Entry 16

By end of session: Hull fully sanded fair and ready for primer; no rough edges or ridges remaining.

— Thursday, November 26 — THANKSGIVING BREAK — No Session —

Session 17 — Thursday, December 3

Phase 6: Finishing Focus: Primer Application

Accomplish this session:

  • [ ] Mix marine primer per manufacturer instructions — confirm USA-made product

  • [ ] Apply primer to full hull exterior using roller; cut in corners and edges with brush

  • [ ] Maintain a wet edge to avoid lap marks

  • [ ] Allow first coat to flash to touch; apply second coat if time allows

  • [ ] Inspect primed surface under good lighting for any remaining low spots, pinholes, or runs

  • [ ] Apply spot fairing compound to any newly revealed defects; sand when dry

  • [ ] Write Journal Entry 17

By end of session: Full hull exterior primed with at least one complete coat; any final defects identified and addressed.

Session 18 — Thursday, December 10

Phase 6: Finishing Focus: Final Paint (USA Theme) & Hull Completion Phase 6 Checkpoint — Hull Complete

Accomplish this session:

  • [ ] Apply final topcoat — base color first (full hull)

  • [ ] Allow base to flash; mask color break lines for secondary USA theme colors

  • [ ] Apply red and white (or blue) accent colors per design

  • [ ] Apply non-skid additive to all walking surfaces — casting deck, flooring

  • [ ] Remove all masking tape carefully

  • [ ] Final inspection — touch up any runs, holidays, or color bleeds

  • [ ] Guest signatures on transom interior (permanent record of everyone who built this boat)

  • [ ] Complete full build photo documentation set — all angles, interior and exterior

  • [ ] Submit final report

  • [ ] Write Journal Entry 18

Hull is complete when: Fully painted in USA theme; all surfaces smooth or non-skid; all custom features installed; final report submitted.

Detailed Phase Plan

Phase 1: Setup & Planning (Sessions 1–3 | Aug 6–20)

Goal: Safe, organized workspace ready to build. All components verified. All customizations designed and materials ordered.

Tasks:

  • [ ] Complete shop safety orientation; sign safety checklist

  • [ ] Set up workbenches, tool stations, and chemical storage

  • [ ] Unpack all CNC panels and cross-reference against parts list

  • [ ] Label all panels (chalk or tape)

  • [ ] Photograph complete kit inventory

  • [ ] Finalize interior customization design sketch

  • [ ] Identify all USA-made materials and hardware

  • [ ] Complete material procurement list

  • [ ] Place orders for any long-lead materials (foam, epoxy, paint, hardware)

Success Criteria: All panels accounted for and labeled; customization plan complete and documented; all materials ordered or on hand.

Phase 2: Stitching (Sessions 4–6 | Aug 27–Sep 10)

Goal: All hull panels stitched into correct shape and geometry verified.

Tasks:

  • [ ] Set up building supports/forms on shop floor

  • [ ] Dry fit all hull panels and verify alignment

  • [ ] Mark all stitch points (every 6–8 inches)

  • [ ] Drill stitch holes along all seams

  • [ ] Stitch hull bottom centerline

  • [ ] Stitch port and starboard sides to hull bottom

  • [ ] Stitch transom into position

  • [ ] Stitch bow panel

  • [ ] Stitch any remaining structural panels (chines, spray rails)

  • [ ] Verify symmetry: measure beam at 3+ stations; verify equal measurements port/starboard

  • [ ] Trim all zip tie tails

Success Criteria: Hull holds its full shape; beam measurements symmetric at all stations; no visible panel misalignment.

Phase 3: Framing & Epoxy Seams (Sessions 7–9 | Sep 17–Oct 1)

Goal: All frames and bulkheads installed; all interior and exterior seams filleted with thickened epoxy.

Tasks:

  • [ ] Fit, trim, and install all frames and bulkheads per plans

  • [ ] Verify frame spacing and plumb

  • [ ] Mix and apply thickened epoxy fillets — all interior seams

  • [ ] Mix and apply thickened epoxy fillets — all frame-to-hull joints

  • [ ] Mix and apply thickened epoxy fillets — all exterior chine seams

  • [ ] Apply keel fillet (full length, generous radius)

  • [ ] Inspect all fillets for voids; touch up as needed

  • [ ] Log all epoxy mix batches (ratio, temperature, pot life)

Success Criteria: All seams have consistent, full-radius fillets. No voids or gaps. All frames are square and bonded.

Phase 4: Epoxy Sealing & Fiberglass (Sessions 10–12 | Oct 8–22)

Goal: All wood surfaces sealed; all structural areas reinforced with fiberglass cloth.

Tasks:

  • [ ] Apply 2-coat epoxy seal to all interior surfaces

  • [ ] Inspect for dry spots and re-coat as needed

  • [ ] Pre-cut all fiberglass cloth panels (interior and exterior)

  • [ ] Wet out and apply fiberglass cloth — hull bottom interior

  • [ ] Wet out and apply fiberglass cloth — bilge/keel area

  • [ ] Wet out and apply fiberglass cloth — transom interior

  • [ ] Wet out and apply fiberglass cloth — hull bottom exterior (full coverage)

  • [ ] Apply fiberglass tape — all exterior chine seams

  • [ ] Apply fiberglass cloth — transom exterior

  • [ ] Inspect all glass work: no dry spots, no major air inclusions

  • [ ] Sand any rough edges or high spots from cured glass

Success Criteria: All required areas glassed. Glass is fully wetted out with no dry sections. Cured glass is solid and firmly bonded.

Phase 5: Custom Build-Out (Sessions 13–15 | Oct 29–Nov 12)

Goal: All custom interior features built and installed; all accessory mount locations reinforced.

Tasks:

  • [ ] Transfer design sketch to hull — mark all compartment walls and livewell location

  • [ ] Cut and fit storage compartment dividers

  • [ ] Epoxy-bond all storage compartment structures

  • [ ] Cut livewell opening; fit and bond livewell liner

  • [ ] Mark livewell drain and supply locations

  • [ ] Epoxy seal all new wood in storage and livewell areas

  • [ ] Cut casting deck panels to fit

  • [ ] Install deck support cleats

  • [ ] Epoxy-bond and glass casting deck

  • [ ] Install all rod holder tubes at planned positions

  • [ ] Install rod holder backing plates with wood doublers

  • [ ] Fabricate and install Power-Pole mounting bracket (transom)

  • [ ] Install trolling motor backer at bow

  • [ ] Mark and reinforce jack plate mounting location

  • [ ] Document all USA-made hardware installed

Success Criteria: All custom features installed and epoxy-bonded. All accessory mount locations reinforced and ready. All new wood sealed.

Phase 6: Finishing (Sessions 16–18 | Nov 19–Dec 10)

Goal: Hull fully sanded, primed, and painted in USA theme. Complete, photo-documented.

Tasks:

  • [ ] Inspect full hull for bumps, voids, and surface defects

  • [ ] Apply fairing compound to any low spots; sand flush

  • [ ] Block sand full hull exterior: 80-grit → 120-grit → 180-grit

  • [ ] Hand sand edges, corners, and tight areas

  • [ ] Wash hull and allow to dry

  • [ ] Tape off non-paint areas

  • [ ] Apply marine primer — full hull exterior (USA-made)

  • [ ] Inspect primed surface; address any remaining defects

  • [ ] Apply final topcoat — base color

  • [ ] Mask for secondary colors; apply remaining USA theme colors

  • [ ] Apply non-skid additive to all walking surfaces

  • [ ] Remove masking; final inspection and touch-up

  • [ ] Complete build photo documentation set

  • [ ] Guest signatures on transom interior before final coat

Success Criteria: Hull is fair, evenly painted in USA theme colors. All surfaces smooth or properly non-skid. Build complete.

Material Procurement Plan

Kit (Already Purchased)

  • Salt Boatworks FRS 16 Plywood Kit (CNC-cut panels, USCG foam, capacity placard, HIN)
  • Source: Salt Boatworks — saltboatworks.com
  • Purchased from: Adam Parchman, Founder

Additional Materials to Procure

Item Specification Qty USA-Made Target Status
Marine epoxy 2-part epoxy system, ~12 gallons 1 set Yes To order
Fiberglass cloth, 6 oz Woven, ~50 yards 1 roll Yes To order
Fiberglass cloth, 10 oz Woven, ~55 yards 1 roll Yes To order
Fiberglass tape, 4" Biaxial or woven 1 roll Yes To order
Silica (cab-o-sil) Thickening agent 1 lb Yes To order
Wood flour Thickening agent 1 lb Yes To order
Expanding foam USCG-compliant flotation, ~10 cu ft Per kit Yes Check kit
Marine primer Full hull, 2 coats 1 gallon Yes To order
Marine topcoat paint USA theme colors (red, white, blue) 2–3 gallons Yes To order
Non-skid additive For deck and casting surface 1 lb Yes To order
Rod holders Flush mount, stainless 4–6 Yes To order
Livewell kit Pump, aerator, drain 1 set Yes To order
Power-Pole bracket Transom mount 1 — To order
Trolling motor bracket Bow mount 1 Yes To order
Jack plate Motor setback 1 Yes Spring 2027
Marine electronics Fish finder, GPS TBD Yes Spring 2027

USA-Made Product Sourcing Policy

Where possible, all materials and hardware should be sourced from USA manufacturers. Document the country of manufacture for each major purchase. If a USA-made option is not available or practical, document why.

Schedule Risk Management

Risk Mitigation
Epoxy or material delivery delay Order all materials by Session 2 (Aug 13)
Extended cure times in cool weather Monitor garage temperature; use epoxy rated for lower temperatures if needed
Session cancellation (illness, weather) Journal entry still required; adjust schedule to compress next session
Fitting issues requiring rework Build 1 session of buffer into each phase; Phase 5 is most likely to need extra time

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