Pop 25 building manual

The Pop 25 now has an illustrated building manual written in English. While the first boats of the class were being built, we learned about the doubts our clients were facing during their construction, and concentrated on those topics so not to leave other builders with extra difficulties.

We also discovered that our intention of designing the boat for electric auxiliary propulsion was shared with very few of our clients, most preferring to use a conventional sailboat diesel engine. Since we design for others, and not to please ourselves, we felt the need to produce new sheets dealing with the auxiliary diesel engine installation, so we added three more sheets to the project showing in details the changes required for the installation of the motor in the engine compartment.

The updated list of plans is this:

1 – LINES PLAN
2 – SAIL PLAN
3 – INTERIOR
4 – DECK PLAN
5A – SRUCTURE – SIDE VIEWS
5B – STRUCTURE – DECK AND INTERIOR
5C – STRUCTURE – TOPSIDES
6A – TRANSVERSE SECTIONS #1 AND #2
6B – TRANSVERSE SECTIONS #3 AND #5
6C – TRANSVERSE SECTIONS #5 AND #6
6D – TRANSVERSE SECTIONS #7 AND #8
6E – TRANSVERSE SECTIONS #9, #10 AND 10.7
6F – PLYWOOD CUT-OUTS AT STATIONS
7 – KEELS
8A – RUDDERS
8B – TILLER
8C – RUDDER CONSTRUCTION PANELS
9 – CUSTOM FITTINGS
10 – SLIDING HATCH AND HATCH COVER
11 – STEM, STEM CAP AND BOWSPRIT
12A – DIESEL ENGINE INSTALLATION – DIRECT PROPULSION
12B – DIESEL ENGINE INSTALLATION – SAIL DRIVE
12C – DIESEL ENGINE COMPARTMENT

Those who are already building the Pop 25 and would like to receive these extra plans (12A, 12B and 12C) and the building manual, which didn’t exist up to now, they just need to inform us and we send on-line to their e-mails with no cost.

INDEX

Chapter 1 – Introduction
Chapter 2 – Tools used in the construction
Chapter 3 – Information about wood, plywood and epoxy
Chapter 4 – Pre-fabrication of the transverse structure
Chapter 5 - Assembling the hull
Chapter 6 – Constructing the interior
Chapter 7 – Building the superstructure
Chapter 8 – Auxiliary propulsion
Chapter 9 – Electrical system
Chapter 10 - Plumbing
Chapter 11 – Building the keels and rudders
Chapter 12 – Finishing, painting and fittings installation
Chapter 13- Appendix
Chapter 1 – Introduction

This building manual was written having in mind affording the possibility of building a low cost and easy to make offshore sailboat capable of performing ocean passages in comfort and safety.

Our challenge when producing this manual had two goals: the first priority was to design a seaworthy craft with accommodations below-decks seldom found in boats of this size; in the second place we wished to offer to the beginner a comprehensive and easy to be followed manual. Since we have large experience with projects for amateur construction and are specialized in designing offshore cruising sailboats, this proposition was a hurdle we were confident that we could overcome.
What came out to be a novelty in our approach was the way we decided to present our work. As the old saying states, a figure is worth a thousand words, and this was exactly what we tried to do.

After producing the virtual assemblage of the project in the computer, we illustrated the whole construction with sketches and rendered images, step by step, resulting in a text that the most inexperienced builder wouldn’t find difficulty in understanding.
Besides this new style of building manual presentation, we also tried to innovate in relation to the building method chosen for the project, bringing new ideas to the boat’s concept more tuned with the present times, like dispensing the use of fossil fuels, not necessarily requiring boatyards for hull maintenance, specifying positive flotation cells along the various compartments of the boat, so to turn it to be unsinkable, and other unique characteristics.

We wanted to design a sailboat with some modern trends, like twin keels, twin rudders, delta shaped beam distribution, sail plan with no backstay, fixed bowsprit and electric auxiliary propulsion, employing a motor with regenerative function, being able of charging its battery banks while propelled by its sails.

This manual has tips for the inexperienced builder that we insist categorically that shouldn’t be neglected, like saturating all parts of the interior surface with epoxy resin, sheathing the outside of the boat and the interior of the tanks with fibreglass, also saturated with epoxy resin, and many other hints like these.

We made this manual with the intention of providing our builders with the most complete set of information so that the finished boat represents a worthwhile investment at the end.

Our first and foremost objective when developing this project was to provide plans for amateur construction of a boat to be used intensively for dozens of years requiring minimum maintenance and providing maximum satisfaction along that time.

Click here to learn more about the Pop 25