: I know of at least three builders who have sealed their SOFs with epoxy. I
: understand that it remains flexible and wont crack - like epoxy that
: happens to get on your clothes. It seems like a very efficient way to seal
: the fabric. Is this a good way to go or am I missing something?
: - Chip

Chip and others,
Sorry I didn't respond yesterday, I just didn't have time to write this:
You don't know how badly I want to just come out and say that epoxy on nylon is the only way to go!, in fact fiberglass is even more incredible!!!, but I can't. I'm just not fully convinced that others wouldn't have problems somewhere down the line. However, I will express my satisfaction with what I've seen (and Chip, I'll send you some nylon to test). I first did a test panel of 8oz nylon and similar weight poly purchased from Dyson in Bellingham before committing to attaching it to a boat. I haven't torture tested this 3'X6' sample, but I have tried many crazy ideas. First thing I noticed was that I liked the way the nylon shrunk to the frame and felt stiff as opposed to the poly that didn't ever shrink quite as tight. Then I started painting different finishes like water and oil based varnishes, LPU, and epoxy over about 6" squares on both materials. My first impression was that it took too many coats with just varnish or LPU on either fabric. Epoxy on the other hand, filled the weave of the cloths on the very first coat. Then I started playing with colors by applying Rit dye to the fabric and also by mixing pigments into the epoxy. Rit dye works well, and although it bleeds terribly, looks fantastic under epoxy. Colored epoxy is cool too. It's thicker and I liked the way it looked with just one coat (still would have to be covered with varnish or other UV protection). Meanwhile, I skinned the short rec boat (Fat Boy) with 8oz nylon using Heat'N Bond tape and stainless staples. One mishap when I torched through the skin near the bow while burning along the sheer to clean it up. That's when I discovered that fiberglass holds well on the nylon also. A quick patch of glass and it was good as new. Back to the test panel. One 6" square with 6oz fiberglass on 8oz nylon and two coats of epoxy does indeed hold together, so much so, that with pliers on a loose edge of glass, breaks the glass clean off around the mouth of the pliers and doesn't delam or affect any other area. Amazing!
After a dark blue epoxy seal coat (and some sponge painting with other colors), I glassed the hull of the Fat Boy. It worked great and seems to be holding up very well. I liked it enough to do again later on the Baidarka and on a 6ft. Baidarka model. It sure seems incredibly tough, but remains flexible. It's much thicker, and I'm sure a bit heavier than other SOF finishes, but I'm happy with it for it's looks and it's durability. You don't see any texture to the fabric and it's a very smooth surface (can't tell there's nylon in there at all). This also allows you to heavily sand the boat without cutting into the fabric. I sanded alot and even took a grinder to get some runs off. All in all it worked out wonderfully. These two kayaks were used quite a bit this summer and they've held up great so far. In the bottom pic, when my son ran across the jagged rock and it scraped hard until he got off it, instead of freaking out, I told him to try that again, and again. Very little damage to the hull, just scratches in the epoxy (with more weight in the boat it could potentially cut deep enough to touch the glass, but I doubt it would scratch through to the nylon. That being said, I suppose we'll have to wait and see. I figure even a drastic puncture through the hull could be patched as in the upper photos.
I think we still need to do alot of testing before builders actually coat their SOF's with epoxy or use fiberglass in the layup. Hey, maybe we can convice Rehd to give it the test and see how well it holds up compared to what he's already done. What do you think Rehd ? Is this too bizarre, or would you mind recreating your tests with an epoxied covered panel and another that's glassed? It would sure be nice to hear what other builders think. But as far as longevity, I cannot recommend this as a SOF covering, until people run their own tests or more time passes with the boats that I have. However, I have faith that this will work and will continue to try new things. I like the way cork looks sandwiched between the epoxy coated nylon and outside layer of fiberglass. I'm trying waterbased stains and dyes on the thin cork (1/8") and it holds well to the skin and looks great. Thin foam would also work and may look cool. As it stands, I like cotton fabric the best because of all of the available patterns. The model (red boat in the pic) has a cool red/burgandy bubbles fabric on the deck and looks pretty neat, almost manufactured, but funky. Looks like it's time to update some photos.
The only advice I can think of while applying epoxy to nylon or cotton fabrics, is that it needs to be massaged into the fabric. In fact I think that a wet layup works best. Coat the nylon surface with epoxy, then lay the dry fabric onto the boat, then just barely use enough epoxy to keep the chip brush wet while you press the fabric down and wet it out from below. Quick, easy, and has a professional appearance. Who could ask for anything more? I'm not convinced that glass is even necessary, but it sure seems to be tough. We'll see.
Another mouthful....Sorry it's so long.
Scott