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Measuring and cutting out the transom
Of all the jobs in this project, the transom is the one which I was most concerned with getting right. I'm not an engineer but I think it's obvious that this part of the boat structure is subject to enormous forces and is worth spending the extra time to get a perfect job.

First of all I made a template out of cardboard which my fiberglass supplier gave me. As a starting point I traced the template with the fiberglass pieces I managed to peel off whole from the old transom. I then fitted the template to the boat and trimmed a bit off here and there to make it as close to a perfect fit as I could. On one side the template was a bit short so I had to tape an extra piece of cardboard on the side and trim it back to fit.

The transom is made from two layers of plywood, 19mm and 12mm making a total of 31mm. The old transom was 35mm thick however I have to allow for the layers of fiberglass which I use to laminate the timbers together and to the boat. The transom CANNOT be thicker than the original or the deck won't fit back on so you are better off being a mm or so thinner than too thick.

I laid my ply on sawhorses and brewed a misture of poluester resin and 25% styrene. This thins the resin down and allows it to penetrate the timber improving it's water resistance and bonding qualities. You don't need to make too much of this resin up (as I found out) and a little goes a long way. I painted both sides of the plywood sheets and allowed them to dry.
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