Coosa Board for Boat Building and Repair
Coosa Board is one of the composite materials I use most often for structural boat building and fiberglass repair. Across my sailboat and trawler restorations, I’ve used Coosa Board to replace rotted plywood, rebuild fiberglass-cored structures, fabricate bulkheads, construct pilothouses and hardtops, reinforce hull structures, and build waterproof interior components. The projects below show real-world examples of Coosa Board boat building and repair, including how the material can be cut, shaped, curved, bonded with epoxy and incorporated into fiberglass construction.
Coosa Board is 30-40% lighter than marine plywood.
It’s waterproof, rot proof, and easy for the amateur.
Coosa Board Projects
Composite Pilothouse Construction — Coosa panels, epoxy and fiberglass used to fabricate a complete pilothouse.
Trawler Hardtop Construction — Coosa-on-frame construction, panel joining and kerf cutting to produce curved structural surfaces.
Fiberglass Core Repair — replacing deteriorated plywood around portholes with Coosa, epoxy and fiberglass.
Structural Bulkheads & Cabin Steps — finished structural Coosa components shaped, fiberglassed, faired and painted.
Structural Bulkheads & Cabin Steps — finished structural Coosa components shaped, fiberglassed, faired and painted.
Boat Bathroom & Shower Structure — waterproof composite bulkheads and structure replacing conventional wood construction.
Dinghy Structure & Flotation Compartments — Coosa incorporated into lightweight structural components and watertight compartments.
The complete step-by-step process is available in the MotorCity Boat Werks Technical Library. Watch the video below for detailed project steps and solutions.
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