Hovercraft


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This is where it all begins. Sections of plywood were cut to form the 5ft. x 10ft. base. Sections were then fiberglassed together. Another view of the plywood glassing. 1.5 oz./in. fiberglass was used to connect the 3 pieces together. Skirt attachements. Small 1/4" strips to be attached to the outside edge of the bottom of the plywood base.
To show the scale of the plywood stips. These were awful to cut on a table saw. Make sure you are using two other pieces of wood as guides (not your hands!) Skirt attachments are attached very carefully using very small roofing nails to the outer edge of the plywood. Another shot of the skirt attachements and plywood base.
Picture of the styrofoam (Dow Styrofoam!) cut in similar sizes to the plywood, but just smaller to accomodate the skirt attachments. Styrofoam together. After epoxying the entire bottom of the plywood as well as the styrofoam the two were sealed together using this makeshift vacuum bag. Plastic sheet was purchased and taped around all the edges. A plastic hose was then connected to a vacuum to keep a co
Another shot of the vacuum bag. Another view of the bottom skids being attached. This is how the bottom skids were attached. The styrofoam gave a raised surface for the craft to skid on. Tubs are filled with water to put constant pressure on skids during attachment.
Large hole to the right was cut just in front of the rear skirt attachment. This is used to fill the space under the craft with air. The hole to the left fills the outer skirt with air and blows it up like a balloon. The idea here is that the skirt is View of the base of the hovercraft from below. Another view from underneath the craft. Some bondo was used to smooth out the transition from the skids to the base (see brown colored material).
Another view of the bottom of the craft. Attachment of the engine mount. It was difficult to get it to stay in one spot, so we used another piece of wood to just loosely brace it. Contruction of the cockpit. The 1/8" marine grade plywood bends nicely to form this shape of the cockpit.
View from behind of the cockpit. Another view of the construction of the cockpit. Fiberglassing the airbox in the back.
Attachment of the upper side strings on the cockpit. This is for added strength and as a mount for the top panel on the cockpit. They were cut to about 3/8" thick, maybe even a little smaller so they could bend. All-star Tom Babinec fiberglassing the airbox. First with a 6 oz./in. glass then topping it off with a 1.5 oz./in. glass for added strength and smoothness. View of the glassing on the airbox and of the engine mount plate.
Attachement of the front brace for the upper cockpit panel and handle attachment. Another view of the airbox and how the air is ducted under the craft. Craft construction from behind.
Engine mount fins are glassed in place to add additional support to engine mount. Another view of the engine mount fins. Creating the inner plywood ring for the thrust duct. We created a 36 1/2" circle and then wrapped the plywood around it nailing it around so it made it easier to wrap. I love how this stuff bends.
Another view. In this one you can see how the plywood was glassed together using the 1.5 oz./in. fiberglass. View of thrust duct with stryrofoam mounted on plywood. Notice how the duct is shaped like an inverse airplane wing. This is so air travels faster through the duct and more air enters. Nylon straps used to mount the outer styrofoam to inner plywood ring.
Another view. One more. The base of the styrofoam was cut off to sit flat on the base of the craft.
Thrust duct. The glassing on the duct was entirely 6 oz./in. From behind. Rear section removed to allow room for the airbox.
Section of thrust duct removed. KEEP THIS! More on that later. Attaching the upper rudder mounts. See quick grips inside thrust duct. View of upper rudder mounts from behind the craft.
More mounting of the engine. Skirt attachment. More skirt attachment.
View of craft with skirt on at night. More hovercraft...she's so close. From behind.
Vacuum bagging the rudders. Similar process to the base, but on a smaller scale. Rudders after vacuum bagging. The excess was cut off. 1.5 oz./in. fiberglass was used on the rudders. And still some more.
It got a little complicated so Martha had to take charge. Still late...mounting the engine. Putting the engine on late into the night.
It was messy. Just needs a paint job now. Underneath the craft.
From beneath the airbox. Registration number. This baby is legal. Picture of the handle on the front and registration numbers. I still love those colors.
   
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Description: This one is a classic.
Location: Midland, MI