Not for nuthin'…. But….. if you’re stretching marine plywood past eight feet on a Chamberlain Marblehead gunning dory — or any boat panel that has to bend fair — a butt block will leave you a hard spot and extra weight. A proper scarf won’t. Today’s tip: cut an accurate 8:1 plywood scarf with a simple shop-made 1:8 rail jig, then glue it so it disappears into the panel.
Why it matters: boatbuilding plywood comes in eight-foot sheets, and dory planking and bottoms often want more length than that. WEST SYSTEM / Gougeon Brothers recommend an 8-to-1 bevel for plywood scarfs in boat work — scarf length equals eight times the panel thickness. On ¼″ ply that’s a 2″ bevel; on ½″ ply it’s 4″. Matching identical bevels, bonded with epoxy, stay strong, stay light, and don’t telegraph a knuckle when you wrap the panel around a mold.
Materials
- Marine plywood panels to join (example below uses ¼″)
- ¾″ plywood scraps for the jig (base, two side rails, end stop, hold-down cleat)
- Marine epoxy resin + hardener
- Unthickened epoxy for wet-out; thickened epoxy (colloidal silica / wood flour blend to mayonnaise consistency) for the bond
- Plastic sheet or packing tape (non-stick under the joint)
- Wax paper or peel ply for the clamp face (optional)
Tools
- Sharp block plane and/or power plane (and a smoothing plane if you’ve got one)
- Straightedge and sharp pencil / marking knife
- Clamps (bar or C-clamps) and a flat clamping board
- Hard flat sanding block (80–120 grit) for final true-up
- Mixing sticks, disposable brush, gloves, dust mask
Steps
- Lay out the scarf. Mark a line across each panel end at L = 8 × T. For ¼″ stock, that’s 2″ from the end. That’s your feather-edge limit.
- Build the 1:8 rail jig. Base about 12″ × 24″ of ¾″ ply. Rip two side rails so their top edges slope at 1:8 (rise T over run 8×T — about 7.1°, but you don’t chase the degree reading). At the scarf start the rail top is flush with the panel’s top face; at the feather edge it meets the base. Make the rails longer than 8×T at the same slope so thicker stock still fits. Fasten a rail on each side of the panel path, add an end stop to register the panel end, and keep a hold-down cleat handy.
- Clamp the panel flat. Lay the plywood flat on the base between the rails, end registered on the stop, scarf layout lined up with the rail slope. Clamp firm with the cleat — the panel must stay flat; it does not ride a ramp.
- Plane the bevel. Set the plane so its sole spans both rails and rides on them. The rails are the depth stop: you can only cut down to the 1:8 line. Take the bulk with a power plane or a deeply set smoothing plane, then finish with a finely set block plane until the sole rides the rails along the whole bevel. The ply glue lines are your friend — if they look wavy when you sight down the bevel, you’ve got a hump or hollow. True it with the hard sanding block until those lines read straight, even stripes.
- Cut the mating bevel. Same jig, other panel — identical bevel, not a “good enough” cousin. Dry-fit on a flat surface. Feather edges should meet clean with no gaps and no overlap.
- Wet out, then glue. Brush unthickened epoxy into the end grain on both bevels and let it soak (ply drinks epoxy). Re-coat if it goes dull/dry. Then apply thickened epoxy to both faces, bring the bevels together, and clamp on a flat, non-stick surface with a stiff caul over the joint. Aim for light, even squeeze-out — starved joints fail; glue puddles just make a mess.
- Cure, then fair. Leave it alone for a full cure per your epoxy’s schedule. Scrape/sand the glue line flush. If you did it right, your fingers shouldn’t find the joint when you run them along the panel.
MOAM’s shop note: Don’t “eyeball” a steeper bevel to save length. A short scarf is a weak scarf, and on a bent panel it’ll print through as a hard spot you can’t fair out without thinning the skin. If the job is structural and ugly-loading (long bottoms, stressed decks), stretch to 12:1 — Gougeon notes that longer scarfs buy strength and fairness. Keep the plane iron sharp; plywood glue lines eat edges for breakfast.
MOAM Out.






