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16' San Juan Dory Construction
Custom wood boat building

Photos of building San Juan Dories
That's plural, so expect to see some differences between boats

Here we see a dory with chines and topsides installed. After planking the topsides, we poured foam in the center seat compartment, which already has its sides and top. You can just make out the limber channels on either side of the foam. We will foam the aft compartments after the boat has been rolled over, because we haven't installed those tops yet. The frames are gray because we painted them with gray epoxy primer before we set them up.

Now the planking is finished, and we've planed the flat on the stem for the stem cap, which goes on later. We will glass this boat, so we put a coat of epoxy resin on the whole exterior. It'll be a lot smoother after we sand it. We've also drawn frame lines on the planking, so we can see them to install the spray rails after the boat's been glassed.

Now the glassing, resining, and sanding is all done. The white stuff on the corners is epoxy putty. We rounded all the corners before glassing, and then built them back up with putty so it will still look like a wooden boat, and the chine guards will actually be on the chines. That's a bunch of work, but it's worth it. Those sticks lying on the horses beyond the boat are the spray rails. It's important to protect that glass with some wood on the outside.

At this point, we've put the protective wood over the glass, applied an epoxy undercoat to the whole exterior, and Awlgripped the bottom. We'll put a boot top between the bottom and topside paint, so it's convenient to paint the bottom first like this. The undercoat looks two toned because we only sanded it where we had to.

The boat has just been rolled over. We haven't removed the jigging legs yet. You can see the blocking between the frames outboard of the aft seats. We will install those aft seat tops as soon as we have foamed the rear compartments.

This boat has had the jigging legs removed. Most of the work you see was done with the boat upside down. This is easiest, once you get used to working this way. All the glue drips onto the floor, for one thing.

Here we see the same thing from aft.

Bang, she's almost done and we are getting ready to spray undercoat. The guards, inwales, and all the trim are masked off.

Same thing from the stern. We've set the bow compartment hatch in place for the photo. Those white things on the transom are brass boat drains, masked off for the painting.

Detail of a section of the starboard seat. Inwale above the seat is covered in masking paper.

This home builder chose to use a center console with a couple of stern seats. This worked out very well. He also chose to use a capped gun'l. Nice job, huh?

Here's another photo of the center console boat, showing his treatment of the splashwell. He added stern decks on either side of the splashwell, like we do on our larger boats.



For brochures on semi-custom wood boats or further information on our custom wooden boat building and design services, please email us by clicking on the E-MAIL icon below, or inquire by mail to:

Nexus Marine Corporation   Phone 425-252-8330
3816 Railway Ave.    
Everett, WA 98201-3838 Email to Nexus Marine Corporation
service (at)
Custom wood boat builders!

We are located on the Snohomish River in the Pacific Northwest, about 20 miles north of Seattle.
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