Setting Up Your Small Workshop
by Dale Hedtke
Boatbuilder, UBI Volunteer

I have the chance to speak with lots of people about building small boats and there are a few subjects that come up again and again. Where can I build? How much space do I need? Will I stink out my family with the fumes? What is a good layout for the shop? Does anyone rent building space?


You would be surprised how many spots there are to build a boat, especially if you can convince your family, landlord, parents, etc. that Noah was right, the tide is rising, you'll not make a mess, etc. The very minimum space you need to build a small boat is about 4' longer than the boat and about 3' on each side. More room is, of course, desirable. Often it is necessary to fit a full sheet of plywood to the boat for marking, so consider if you will have enough side space. If space is limited, you can usually cut the plywood to rough shape off the boat, and then fit it into place. You will most likely need a workbench near the boat as well. If the boat you are building has planking to be installed, a long narrow bench next to the boat is ideal. If space is tight, consider hinging the bench against the wall so it can be moved out of the way when necessary.

Here are some possible building areas: basement & laundry room, an unused bedroom, the attic, a 3-season porch, the garage, a neighbor's basement, etc. (heat is necessary during glue & resin curing stages only.) The main requirement is that you can get the completed boat out! Measure the windows and their rough openings. It may be feasible to remove a basement window frame and pass your boat out through the rough opening. Perhaps you will need more than one work site, depending on the phase of construction. Assemble (plank, strip, wire, etc.) the boat in the den, move to the garage to sand, back to the den for glassing, etc. If you are working on a small boat in a garage, you may be able to hoist the boat overhead for storage between work sessions. This will, of course, depend on the type of boat you are building (does it need a strongback and forms?) and the building stage you are at.

Finding a rental space to build is a very attractive proposition to many builders, but building space is fairly difficult to find. Builders that are taking on big boat project often need to build off-site because of space restrictions. Check with outfits that have warehouse or studio space for rent. Also look for a small garage that can be rented for a few months. Maybe your employer will let you use a section of a shop, warehouse, etc. Check with local boat yards; they often rent space for larger projects. Finally, consider fabricating a temporary structure in your own back yard. You can use greenhouse plastic over lightweight wood frames. The boatbuilding magazines have advertisements for these kinds of shelters.

Make sure you have good lighting; I am constantly amazed at the (avoidable) mistakes that I make just because I didn't have enough light. If you are setting up a permanent shop, install several 4' fluorescent lights - the cheap ones you can buy at the building centers. For a temporary solution, the aluminum reflectors with a clamp arm are effective, easy to mount, and convenient to reposition. Another great choice is to mount high output halogen lamps on portable stands. These provide large amounts of light (and heat) and can be positioned for best advantage. By the way, if you are painting, be sure to have 1 or 2 lamps at a low angle; this will help you see how the paint is going on and if you have any drips or runs in the paint.

I keep all my epoxy supplies on a rolling metal cart. The cart I use was popular in the 50s in kitchens and they show up at garage sales. I keep the resin, hardener, gloves, stir sticks, fillers, FG tape, plastic spreaders, rollers & covers, and brushes on it. Most epoxy resins do not have a strong odor, and it is possible to work in the basement or attached garage without objection from those living in the house. As with any chemical, it is important to provide some positive ventilation in the workspace. However, working with polyester resin and most paints is another story. The smells (from offgassing solvents, etc.) are unpleasant, and can be harmful to your health. Your own situation will dictate what your ventilation requirements will be, but I recommend point-of-work dust and fume pick up where possible, wearing an OSHA approved dust and organic vapor respirator, and using fans and windows to exchange the air in your work space frequently. Planking a boat is not especially messy or dusty. Sanding the outside can be accomplished using a sander with a dust collector attachment (minimum airborne dust). You can usually get away with 'glassing the hull with epoxy if you are in or near living quarters; the smell is usually not objectionable. Just be sure to provide ventilation when you are working with resin. Sanding the inside can be messier, because it is harder to get a disc sander with dust collecting equipment into the stems. A shop vac with a large filter helps here, and is useful for general clean-up.

Portions of this article have appeared in MCA HUT! Magazine.