- Sun Dec 20, 2015 4:10 am
Laminate the outrigger (called an ama) from high density eps foam and plywood (sort of like a surfboard). The lugs where you will attach the iako (connection poles between outrigger and boat) should be integral to the wood stringer. Then glass the whole thing. If you use epoxy resin instead of polyester resin you will not have to worry about the melting the foam. Finally, paint it with something like Interlux to protect the epoxy from UV.
3 to 4 mm thich Baltic birch plywood is really good for small boat building. You can use it for either strip plank or panels. You can even strip plank with high density foam (3 lb/cu.ft). Either way, glass the whole thing. That is where your strength comes from. Fiberglass cloth comes in a range of weights, e.g. 4 to 10 ounce per square yard. The weight of the resin should be about equal to the weight of the cloth. Several thin layers of cloth/resin is stronger than one thick layer. You can get even more strength with less weight using carbon fiber or Kevlar, but it is too expensive for most.