1. Lay one sheet of exterior grade plywood flat on the ground or upon a floor or deck. Glue with epoxy or polyurethane resin 1"x 1"x 93" flush to the edge of each long side. Glue 1"x 1"x 45" flush to each plywood end. Screws or nails can be used to reinforce connections. All joints may be strengthened with 3" fiberglass tape and resin on inside surfaces.
2. Cut one sheet of plywood into two 2' x 8' pieces. Align long ends of flat plywood sheet with long edge of a cut piece. Glue to 1"x 1" and to full size plywood edge. Repeat for second cut piece. Screw or nails may be used for reinforcement. Set the resulting "U" shape aside.
3. Repeat step 1 with a second full sheet of plywood.
4. Set the "U" shape on the second sheet of plywood to form a long tunnel. Glue plywood edges and 1"x 1" together.
5. Cut four pieces of 1"x 1" to a 21" length and glue these flush to the 2' edges at each end of the plywood tunnel. these should fit nicely inside the existing 1"x 1"s.
6. Cut another sheet of plywood into 2'x 8' pieces. Set one piece aside for use on a second float.
7. Cut one 2'x 8' piece into two 2'x 4' pieces.
8. Glue one 2'x 4' piece to each end of the tunnel, gluing to plywood edges and to the 1"x 1"s.
9. Cover all outside edges with 3" fiberglass tape and two coats of resin.
10. Paint with waterproof paint.
Notes: 2"x 2" wood may replace 1"x 1" for additional support or fastening surfaces.
Paint may be deck, bottom paint, or even several layers of latex house paint.
2. Cut one sheet of plywood into two 2' x 8' pieces. Align long ends of flat plywood sheet with long edge of a cut piece. Glue to 1"x 1" and to full size plywood edge. Repeat for second cut piece. Screw or nails may be used for reinforcement. Set the resulting "U" shape aside.
3. Repeat step 1 with a second full sheet of plywood.
4. Set the "U" shape on the second sheet of plywood to form a long tunnel. Glue plywood edges and 1"x 1" together.
5. Cut four pieces of 1"x 1" to a 21" length and glue these flush to the 2' edges at each end of the plywood tunnel. these should fit nicely inside the existing 1"x 1"s.
6. Cut another sheet of plywood into 2'x 8' pieces. Set one piece aside for use on a second float.
7. Cut one 2'x 8' piece into two 2'x 4' pieces.
8. Glue one 2'x 4' piece to each end of the tunnel, gluing to plywood edges and to the 1"x 1"s.
9. Cover all outside edges with 3" fiberglass tape and two coats of resin.
10. Paint with waterproof paint.
Notes: 2"x 2" wood may replace 1"x 1" for additional support or fastening surfaces.
Paint may be deck, bottom paint, or even several layers of latex house paint.
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