The Cold-Molding Process

The Cold-Molding Process K-16 hull

The process of cold-molding is simply the practice of building up a hull shell or any other structure using multiple layers of thin, vertical grain wood veneers over an open framework, male building mold. The result of this process can be thought of as very high quality, custom shaped marine plywood. To add strength, fiberglass, kevlar or carbon fiber cloth is often applied to one or both sides of the hull shell. Because the thin veneers are so pliable, just about any shape can be formed using this method. While many variations are possible, the cold-molding technique is best applied to high performance boats, in order to create a very light and efficient structure. Often all of the bulkheads and most of the other interior structures such as cabin soles, berths and shelves are bonded directly to the hull shell, unifying the structure and greatly increasing stiffness and strength.

As far as the amateur builder is concerned, cold-molding is a relatively straight forward process. Using full-size patterns or pre-lofted offsets, the construction form goes together quickly. The application of veneer is a rather labor intensive task, but the effort can be spread across short work periods, making it a good method for builders who may only be able to work for an hour or two at a time.

Suggested reading for more information:

Cold-moulded and Strip-planked Wood Boatbuilding by Ian Nicolson
Gougeon Brothers on Boat Construction: Wood and West System Materials by the Gougeon Brothers