Preview: Mastering Epoxy with Russell Brown, Part 1 – An Introduction to Filleting

38 Responses So Far to “Mastering Epoxy with Russell Brown, Part 1 – An Introduction to Filleting”

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  Andrew Blodgett says:

  I needed to make a repair on my wooden boat. I watched the first three of these, a video by West Systems, and a video specific to my boat, and I was all set! I love Russell Brown’s enthusiasm and how he explains everything.

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  Pierre DARDEL says:

  Thank you very much Russell for your encouraging videos : as a matter of fact only a master can demonstrate simplicity when we all know from experience that short timing is stressful when it comes to epoxy 😂🤩

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  Robert Wight says:

  You Tube has numerous takes on building boats. Some very educational with what I would call “newer sponsors” and some that rush through the builds so fast without thorough instruction (and thier work shows it). So far, Off Center Harbor has had videos in which the products used are the products of that I am familiar with. These products are “old school” with proven track records used in the boating world. Maybe I am attracted to these products more than the others.because I have used them. Maybe it is a Northeaster thing maybe it is just my experience in yards and marinas I have worked in. I am so enthralled to have found OCH. Outstanding!

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  Robert Wight says:

  Russel Brown is surely the Master of fiber-glassing. Very detailed instructional tutorial. Make sure you go through all of the videos.

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  Dave Dickmeyer says:

  I love epoxy and have used it for years and have developed similar techniques to what Russell is showing. Kudos to him and OCH for this new video series. I am so looking forward to seeing them! Thanks so much! Epoxy rules!
  (Hopefully I put this in the correct place this time…)

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  Martin Forst says:

  Hi. I don’t know whether anyone can help! I am rebuilding a fibreglass boat from a dead hull. My intention was to use the original as a plug to make the new mould, however one section is so badly damaged, I am now considering recreating a plug completely: plywood and soft wood structures. What would be the best way of ensuring the surface of the new plug is sufficiently hard and smooth (Yes, I know, plenty of sanding and polishing helps!) to be able to take a mould off it? Thanks for any advice. M

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  Nate Rooks says:

  Fernando – you snuck in while they were being tested on the site! They will be released permanently very soon.

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    Fernando Fert says:

    Tanks, must be that.

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    Dave Dickmeyer says:

    I love epoxy and have used it for years and have developed similar techniques to what Russell is showing. Kudos to him and OCH for this new video series. I am so looking forward to seeing them! Thanks so much! Epoxy rules!

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  Rod West says:

  What is peel ply? I normally use packing tape. Works pretty good.

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    Jay Knight says:

    Excellent video, good to see the book come to life! Patiently waiting on his video on his flow coat technique.

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      Nate Rooks says:

      Jay, we have some other installments coming first, but the fill coat video (Part 8) is a good one – a real demonstration of why he’s the master!

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    Nate Rooks says:

    Rod, I use packing tape (as does Russell) for edges or on top of surfaces where you don’t want epoxy, but Peel Ply goes over the epoxied areas.

    Peel Ply is also called Release Fabric, and it’s a synthetic cloth that epoxy can soak through but then be pulled up. It helps prevent uneven epoxy buildup and leaves a uniform surface with only a little bit of texture that can be easily sanded.

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  Dan Yuhas says:

  Russell Brown and OCH,
  Well narrated and well filmed! How long before we can expect the next installments in the series?
  Thanks!

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  Dony Bland says:

  Excellent visual instruction! These instructional series ideas are exactly why I have become a “life member” of OCH , many hearty thanks to all involved, eh mates?
  Ol’Blandy, s/v Spirit , USCG No.1275012

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  Kimberly Young says:

  I have started building my own PT11. Working on prep work for various panels and components at the moment. I’ve done a few small, simple fillets on some parts, but nothing like the larger fillets shown here. This video will come in very handy in a few weeks! :-)

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    Steve Stone says:

    Hey Kimberly, send us photos as you progress. It’d be fun to have an “in-the-wild” sighting of a PT-11 being built.

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  Roger Elmes says:

  Did a lot of West Epoxy interior work on my Big Mac as i converted her after a Vic-Maui Race from racing to cruising; and exterior work like a hard dodger with sliding hatch, a proper cable locker, and a 5 foot sugar scoop extending her to 70′. Even this one little video would lave been a godsend.As we say up here in parts of Canada – merci beaucoup.

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  eugene connolly says:

  Top entertainment and instruction. Nice job. Thanks!
  Gene Connolly

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  Thomas Buzzi says:

  Learned several things from this seven minute video that will help immensely on my next project! Such a pleasure watching a “master”.

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  Burton Blais says:

  Very informative. And, oh man, do I love that PT11!

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  Eric Hansen says:

  Man, I love you guy’s!

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  Larry Cheek says:

  Perhaps Russell will cover this in filleting part 2, but in case not: I’ve found that covering the wet fillet with peel ply works very well, yielding a clean surface without sags and needing very little if any sanding. The larger the radius of the fillet, the more useful it is.

  First clean up all the overrun with a scraping tool as Russell demonstrates, then press a strip of peel ply that’s slightly wider than the fillet into place, using light finger pressure. Press a second time, again lightly, with a wood stick rounded to the radius of the fillet. As soon as the epoxy cures, remove the fabric. Peel ply doesn’t permanently adhere to epoxy.

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    Larry Cheek says:

    One further thought regarding fillet radius: until I started using peel ply I had a tendency to make important structural fillets too small because the epoxy in large ones would tend to run and sag, When the fillet in question is a critical one such as the transom to hull side joint, this is asking for (big!) trouble. Wherever structural integrity is critical, spread the shearing load over more of the plywood surface with a larger fillet. Nobody ever made a boat too strong!

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      Thomas Lyons says:

      If I think a fillet is too small, can I just lay on and shape another lamination to the desired dimension? Thanks..

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        Larry Cheek says:

        I’ve done it. Though if the original fillet is more than 24 hours old the bond between old and new material will be mechanical rather than chemical, so it might not be as strong. I hope Russell will weigh in here with an answer because his will certainly reflect deeper expertise.

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          Nate Rooks says:

          Larry, these are all great points. Russell will cover more about primary and secondary bonding, and while we didn’t use peel ply for these fillets, he does use it – typically on larger fillets where the peel ply’s stiffness isn’t stressed by the radius. Thanks for sharing your thoughts and experiences!

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  Dave Dickmeyer says:

  Awesome! Can’t wait to see the complete series! Thanks guys!

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  Jeff Patrick says:

  I have his book and have read it more than once. But seeing him work is much better than reading instructions of how to work. Very helpful. I hope he takes time to explain more about preparation of the epoxy (goo to filler ratios for instance) and gives tips on smoothing with the rounded stick. In this video he showed how to prep the chisel stick but I have more problems with smooth application than I do with removal of excess.

  So I’m looking forward to this series. As usual the video and sound are great. Thanks OCH!

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    Nate Rooks says:

    Jeff, Russell will indeed share his filler pre-mix methods and ratios in a future installment, as well as more of his technique to get the perfect little “swoose” with the fillet stick.

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  Al Gallant says:

  Really interesting and inspiring. Have been watching Sail Life on you tube also where he has been doing lots with the west system
  . Both have great hints. Thanks!

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  Glenn Holland says:

  Russell, Appreciate it! Very good, clear instruction. And when that bag warms up, get it out quickly or chunk it.

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  Michael Vaughan says:

  Gold!
  Eximious.
  There’s no greater thing that a person can share than their knowledge. Thanks Russell and OCH.

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  David Tew says:

  What a coincidence, and thanks for providing this resource. Yesterday afternoon I was at The Apprenticeshop in Rockland, Maine where a PT 11 Nesting Dinghy kit is well along in construction for a customer. Keven Carney, the instructor, made a point of saying how their booklet describing epoxying techniques (especially how to do it cleanly) was the best instructional reference he’d found on the subject.

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  Sean Carlin says:

  Good stuff there and a great idea for a series! Looking forward to more.

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  Max Close says:

  Very informative,the views and detail are amazing

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  Jameson Bull says:

  I hope there are some tips on how to clean up some of my less than ideal fillets on my Northeaster Dory from last spring. Haha.

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  Casey Haynes says:

  Beautiful…, can’t wait for more…