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Pop 20

How to build the Pop 20

The plans for building the Pop 20 are a sort of kit on paper. All the transverse structural components as well as the stem are given in full size patterns and the other plans show in details how all major components are defined. If CNC cutting is preferred, we can provide the file in CD-Rom instead of the full size patterns The plans are so simple to be understood that written explanations are practically unnecessary.
The full size patterns for cross sections of transverse structure include external and internal cut-outs, discounted sheathing thickness. These transverse structures are made of 15mm (5/8") marine plywood and all it's required to make them is to transfer the full size lines to the plywood and cut it with the jigsaw, the other option being laser cutting. It's even provided a temporary support base on top of each deck beam to attach each bulkhead to the building grid. Notches for longitudinal components, like chines, sheer clamps and stringers are also defined in the full size patterns in their correct positions.
The stem is built using four plywood cut-outs, which are given in full size in a specific sheet, glued one to each other, building up the thickness required for this component of the structure. The forestay chain plate is inserted between the two internal pieces, so it requires no complicate procedures to install this important equipment.
The stem attaches to bulkhead 0 by means of a notch shown in full scale at bulkhead 0, so these two components become firmly fixed one to the other, providing a rigid base to hold the other structural members
After placing the pre-fabricated structure on the building grid, the longitudinal componentents are nailed and glued into their notches at each bulkhead and a plywood keel is laminated in place over the bulkhead floors.
Beveling and fairing required are easily performed and the plywood sheathing is quite easy to be applied, considering that the plywood thickness is only 6mm (1/4")
After applying the plywood sheathing, the hull is covered with two layers of 450g/m2 mat saturated in epoxy resin. The interior is already defined by the transverse structure and requires very little work to be completed. The whole interior must be saturated with two coats of epoxy resin to seal the plywood from moisture, this way assuring a long life to the boat.
Deck is even more straightforward and it also is encapsulated in two layers of 450g/m2 mat saturated in epoxy.
Keel and other fittings are bolted in place and for that matter it's specified the wooden reinforcements that work as back plates for them.


15 mm plywood
stem 2x 15 mm and 2 x 10 mm plywood
Keel 3 x 10 mm plywood
Chines 40 mm x 20mm wooden strips
Sheer Clamps 2 x 40 mm x 20mm wooden strips
Stringers 20 mm x 20mm wooden strips
Hull sheathing 6 mm plywood
Deck sheathing 6 mm plywood
Hull fibreglass sheathing 3 x mat 450g/m2
Deck fibreglass sheathing 2 x mat 450g/m2
Longitudinal furniture 10 mm plywood
Floor boards 10 mm plywood
cockpit floor board 10 mm plywood
bunk boards 6 mm plywood
Furniture structure 20 mm x 20mm cleats
Floors 40 mm thick wooden cleats
central deck stringer 50 mm x 20mm cleats
Deck stringers 20 mm x 20mm cleats
Underdeck reinforcements wooden 20 mm thickness
transom 15 mm plywood