The main frame was constructed with 1 by 3 inch pine.  Frame was secured by cutting cross lap joints and gluing into place.  To create cross lap, joints a jig saw and chisel where used.  Triangle reinforcements were then inserted and attached on all sides of joints to frame rigid and square.

After glue, dried a bottom (plywood floor) was constructed using 1/4 inch plywood.  This wood was then centered and attached to frame using woodscrews.  Excess wood was sanded off.

Sides Front and Back

A template was designed for side supports.  The appropriate number of side supports were cut from 1/2 inch plywood.  Supports were attached to each end of rib on frame using glue and wood screws.

2 air holes were drilled in each side support. This should have been drilled before attachment to frame!! Air holes were cut using a hole saw. Air holes serve two purposes: 1. decrease weight 2. increase air flow in air chambers.

Side and back walls were cut from 1/8 inch plywood and attached to supports using wood screws.  Walls were further reinforced with fiberglass later.

Nose piece was carved into shape and attached to bottom of bow floor. Side panels were constructed from strips of plywood. Plywood worked because it is flexable - idea for a compound curve. String was used to keep strips together while fiberglassing. Note: the added support on frame for drive engine mount.

Fiberglass

All surfaces were then fiberglassed. Care was taken to keep air flow clear.

Skirt Design and Installation

Skirt segments were designed, cut and sewn from neoprene coated nylon. There were 3 different types of segments: A-segments for sides (64 segments total), B-segments for corners (triangular in shape - 12 in total) and C-segments for the back (angled into water to prevent water from entering skirt - 8 in total).

Peripheral jet on single segment. This is angled into center of craft to create greater lift by (creates a bubble, thereby increasing lift from peripheral jet's.

Skirt segments were also fastened to aluminum strips using metal chips.

After location of air holes was determined, holes were cut into hull using a hole saw.

Skirt segments were then attached to "P" clips with zip ties.

Lift Motor Mount and Lift Fan Mount

This hovercraft has a non-intergrated lift system. There are two separate fans: front fan for lift, and rear fan for propulsion. Motor mount was created using 2 by 4's and bolts.  These were then coated with resin to preserve wood.

Assembly for motor mount was designed and constructed. Note torque of the outboard engine was too much for drive shaft. Therefore, modifications were needed. A reduction of at least 2:1 would releave this stress problem.

Although our hovercraft was completed, we encountered one major problem. Our drive shaft of our lift engine snaped while we were doing test runs.