NESTOR

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  CONSTRUCTION PHOTOS  

              ( scarf joint details, typical bulkhead construction )      

              (  assembling the pieces, dry wall screws and wire ties )  

              ( making  epoxy fillets and fiberglassing the hull ) 

            ( seats, sail rig, centerboard trunk and  finishing details )

           ( storage options )

 

        NESTOR 10 is a 10 foot long dinghy designed to split apart and "nest" for easy storage. Nested, the boat requires only 60" of deck space and is less than 22" tall. The bow and stern sections weigh 40 lbs. each, and are easy to lift and assemble. For passages, NESTOR can be fitted with a canvas cover and used to store a variety of deck and emergency gear. The 52" beam, wide bow sections, and hard chine construction give the boat excellent stability and load carrying characteristics. The boats shear and rocker lines have been chosen for good towing and rowing performance. A sailing version is also included in the plans.  NESTOR is a surprisingly large boat, and carries 4 adults with ease. 

        An 8' LOA version, NESTOR 8, is also available.  NESTOR 8 is designed for two adults, has a 44" beam, and stores in a package 51" long by 19" high.  No scarf joints are required for NESTOR 8, the side and bottom panels can all be cut from 3 sheets of 4 x 8 plywood.

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        NESTOR is designed with "fully developable" sections (bending and twisting allowed, but no compound curves), which are required for the "stitch and tape" building method. The panels and bulkheads are "stitched" together and then glued with epoxy. The joints are taped, and a single layer of fiberglass applied to both inside and outside surfaces. No exposed wood, very low maintenance. This also increases the boats strength, and allows for a variety of panel materials. All four bulkheads are cut from ½" plywood, and 1/4" plywood is used for the side and bottom panels.

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Sailing Version

        One interesting variation, my favorite, is to build the sides out of wood strips. The wood strips are edge glued together flat on the floor, then cut to shape and bent into position. The sides are fiberglassed and sanded, but varnished instead of painted. The varnished wood strips will shine like a piece of fine furniture, resulting in a really unique boat. Some true believers even claim that fish prefer the bright finish! My experience with wood strip construction is all positive. They only require a coat of varnish every year or so, and I guarantee the boat will generate a lot of positive comments!

        NESTOR is a good "first" boat, and can be built in around 60 hours. Only standard hand tools and a skill saw are required, and the total cost will be less than $400. Options include a sail rig and the hull can be left in one piece if the nesting feature is not required. Plans are available for $50. Full scale patterns are an additional $20. Deduct 25% for email delivery (MS Word and AutoCAD).

 

Construction Overview

        Stitch and tape construction is simple and the strength of the boat can be "adjusted" by adding additional layers of fiberglass. The bow, center bulkheads (2 req.) and transom are built from ½" ACX plywood (marine plywood is unnecessary). Both center bulkheads are fitted with two 4" wide, ½" plywood doublers. The transom is also fitted with a pair of doublers above the seat, where the engine mounts. The doublers will be much easier to fiberglass if the inboard edge is beveled to 45 degrees.

        Both the inside and outside of the hull are covered with 1 layer of 8 oz. fiberglass, with generous overlaps at all seams. A list of books on stitch and tape / wood strip construction is included at the end of these instructions. If your not familiar with the basic techniques, I recommend buying one for reference and experimenting with some scrap wood. The process is not difficult, but variables like cure time and pot life will depend on the type of resin, amount of catalyst used, and the ambient temperature / humidity. Either polyester or epoxy resin can be used. My recommendation is to use thickened epoxy for all panel bonding and fillets, and polyester for all glass work.

        Assembly is done with no temporary forms, strongbacks, or jigs. All pieces are drilled for nylon wire ties, then simply stitched together. As the wire ties tighten, the panels curve into place, and turn into a rigid structure. When all ties are tight, the boat is turned upright, leveled, and all seams filled with a generous mixture of epoxy, micro balloons and cab-o-sill. The boat is then fiberglassed, inside and out.

 

          NESTOR is a good "first" boat, and can be built in around 60 hours for less than $400. 

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