plywood for antique streetcar

[George]

I'm planning on using 5mm Okoume plywood on the sides on the streetcar I'm restoring at the Science Museum of Va. in Richmond and would like to know what the perferred method of attachment is. the car will be used to take our visitors for rides around a park we're developing.
5mm plywood seems awfully thin for screws. Should nails and glue or epoxy be used ??
Thanks, George

[james_r]

Hi George:

It's hard to give advice without some more information. Are you attaching the plywood to metal or to wood? Do you want to be able to take it apart for future repairs? How was it done originally?

Without knowing more, and assuming that you're attaching wood to wood, I would say that epoxy is probably overkill. A good waterproof glue backed up by closely spaced wood screws and washers should do the trick.

If you can, post some pictures. That would probably generate a few more responses.

james R.
Thanks for your reply. I've replaced the wooden frame work on the sides of the streetcar and will be attaching the plywood to it. I've read that boat rebuilders use epoxy but I guess, since I'm not trying to keep water under pressure out that, would be overkill. Since the original painted surface didn't show any screws, I don't want them to show either. And in my lifetime, I hope the streetcar never has to be taken apart again.

So I guess an exterior glue with countersunk stainless or brass screws is the way to go. I'll have to fill in screws witha material of some kind.

I'll try an attach an image.

Thanks again,
George

[james_r]

Hi George:

I didn't mean to entirely dissuade you from using epoxy. If a true restoration isn't important, and longevity and a surface that doesn't show fasteners are, then epoxy may be a good solution.

You can use clamps, staples, or finishing nails to hold the panels in place until the epoxy hardens. If there are areas that require more holding power you can use screws through scrap pieces of ply to prevent marring the panels and to apply more pressure. Once the epoxy cures just remove the screws and fill in the holes with epoxy thickened with a low density filler.

Look through www.westsystem.com for information about using epoxy. There are other good brands on the market but my experience is primarily with Pro-Set and West System epoxies.

If you decide to use epoxy let me know. I'll be happy to walk you through the steps involved and materials required.

James