Backers

Here are some shots of the backers for the clutches and traveler. They are made of cutting board material, which is easy to shape.

Shine

I was happy to see the reflection of the keel on the bottom after doing the paint. I still have some sanding to do, but this was a nice start:

Hole

Did I say I was changing out my paddlewheel? I glassed the core before installing the new unit. This is what is in there:

Before and After

Took a while, but the bottom is finally almost sorted out. Two coats of Pettit Vivid thinned with xylol at double the suggested rate applied with a foam trim roller and it's pretty smooth.

Blisters Sealed

Was too cold to do too much today. Here are the blisters all filled in and sanded smooth, along with the spots of Rustlok Steel Primer 6980 to seal them.

Lobster Tail

Whoohoo! Put a little blue paint (Blue Vivid was on sale this week) around the rudder tube and installed the rudder. I think this will look pretty cool when I'm done. Boat will be bright blue and the foils yellow. :)

Bottom Update

Been a while since I made a post, but still been working hard. I keep forgetting my camera. Got to be done soon, as races start on 19 March....just a few short weeks left. I must be in the water by the 17th!! Bottom blisters are all filled and sanded smooth, just need to seal the repairs prior to paint. Hole has been enlarged to accomodate a new paddlewheel transducer. Seats are done. Traveler needs to be installed. Keel needs a little fairing and the whole boat needs paint. I've got the rudder in the garage and started painting it there. Using PETIT VIVID (in yellow). I'm spraying the rudder to see how smooth I can get this stuff, but the boat will need to be painted by roller or pad. I thinned the paint with Xylene to the max limit on the label to make it easier to spray. I'm running 45lbs pressure on 100' hose to a 'Harbor Freight' touch up sprayer. :)

Started the port side

The port side only had a 12" square delaminated area. This should be much easier to do than the other side was. :)

Final layer of glass / carbon....

Weather was good again (~45 this morning), so I decided to lay up the final layers of 3K carbon fiber and 14.5 oz glass. The final count is 1 strip 8" 6K carbon fiber as a stiffener under the traveler, 1 layer overlapped 12" 14.5oz glass, 1 strip 4" glass tape under the traveler, 1 layer continuous 3K carbon fiber, and a final 12" 14.5 oz glass strip under the traveler again. Seems pretty tough...I hope it stays together over the racing season. I've got a 12" hole in the seat on the port side I'll do next time I go down...will be easy to do in one layup I think.

New Gauge

Hey, the system is old and beat, but it works and the gauge looks good and pressure seems to read well. 3K PSI max for this boat!!

Backstay Pressure

The contraption in the photo is our old Stearns hydraulic backstay adjuster. The gauge never worked, so I'm replacing it with one from here. http://www.gaugestore.com/gaugestore/97wikpresgau26.html
Nice price, quick ship. I'll let you know how it works out.

Added a layer of 14.5 oz glass

The weather was cool today, around 40. Decided to add the 14.5 oz skin components. I used 12" cloth run transversally in 4 sections for this layer. I also ran a row of 4" tape down the center where I had overlap on the carbon. I wet out the glass on a piece of polyethelyne sheeting, then applied the wet mess by hand. It stuck well and all that was required was a little smoothing. I wore purple nitrile gloves this time....huge difference, no mess. :)

Skin started

Was blowing blue stink today (40 from the north). Working in the boat on stands made me more nervous than I think I would have been sailing in the same conditions! The core appears to have set well in place. Today I added an 8" 6K carbon fiber strap directly under the traveler. I ran it up the back of the seat and down the seat front. This should give me a little extra strength / less flex in this area where the traveler loads are high. Next will come the layer of 14.5oz glass over the carbon and the rest of the seat, and then a final layer of carbon 3K over the whole thing.

Core Set in Place

Was a nice day today...a little too nice, as the temperature approached 60 degrees. The Low Temperature Epoxy I have is good from 38 to 60...eek! After sanding the bulk of the old 'blue cheeze' filler off the deck, I test fit the compression fixture to make sure it would hold everything in place while the epoxy cured.

Next was to mix up the Low Temperature Epoxy and prime the surfaces. This was no big deal, but I did notice that the epoxy did not go as far as I thought it would. Oh well. After priming both surfaces, I added the hardener to the BOG mix I made up front by thickening the part A with colloidial silica...I did this so I would not waste time mixing. The mix was not as thick as I wanted, so I had to go back and add more filler. Again, the bog did not go as far as I thought it would. I pasted the boat surface with one batch, and hit the core with another batch. It was no where near the thickness I originally wanted...I ended up with about a millimeter thick layer on everything.

I hope it's enough! It was enough to hold the core in place without support. After sticking the core up, I pressed it in place with a hydraulic jack and a length of 2x4 pressing just the foam board. The thing I made earlier with the luan was too stiff and I needed too much pressure to get it to conform to the seat. The foam ended up working well. I squeezed it gently and just enough to get epoxy to ooze out around the edges a little. After that, I filled some hardware holes on the deck with epoxy to keep the water from getting in to the core. I plan to pull all the hardware eventually....but time limits me and I'm doing the high priority stuff 1st. Oh, BTW, a dixie cup of the Low Temp epoxy with no filler at 60 degrees will get so hot you can't hold the cup!! It is definitely not good unthickened at warm temps.

Some January Progress

Built the form today to press the balsacore into place once everything else is ready to go. I used 1/2" blue foam board cut as a template for the core material. That was pretty easy. The form is just a section of thin luan plywood cut to size. The idea is to press the core in place into a good epoxy bog and press it with light pressure from a hydraulic jack. It will take the slight curve of the seats from the pressure. The form is covered with polyethelyne plastic and will be reused to hold the skin on during the next step.

This was a bigger mess than I thought

I used a dremel with a large abrasive cutting wheel to cut the bottom laminate. I removed about a 40" section, the whole 18" width of the seat. I wanted to make it smaller, but the core was wet everywhere I went. I'm not in the mood to replace the entire seat, so I'll do this big section under the traveler and a smaller section on the port side and call it done. Although wet, the core was NOT easy to remove at all!! I thought I was going to re-use the skin - NOT - it was totally destroyed in the removal because the core was stuck so well to it. The only reason I did this repair was because it was under the traveler and the seat flexed under foot. Even when wet, the Klegecell core holds up pretty good. Oh, and the garbage bag full full of wet core weighs a ton!



This is what it looks like when it comes out.

Cockpit Prep

Prior to removing the interior skin of the seat, I screwed a 2x4 to the top where the traveler goes so the to surface would retain its shape...nice and flat for the traveler.

Just a few more

Well, there were more there than I thought...but figure I better get them all now while I have time. This is about two thirds of them. There are just smaller ones left that will be easier to get done, now that I have the technique down. The tool of choice is a dremel tool with the small drum sanding bit. Takes them down in a hurry with coarse paper. :)

Some progress

Spent a few hours today grinding out some 40 more of the blisters. Sizes ranged from the size of a dime and 1mm deep to a couple inches across. Most are in the top couple layers of glass and the size of a quarter when cleaned up, but a couple were deep. None go through to the core that I have found and all can be ground dry. :) The hull construction is interesting. There appears to be no gelcoat, just a thick layer of baltiplate under some regular antifoul. There are at least three layers of ~6oz cloth over a light mat before you get near the core...and there might be another layer of cloth against the core, but I have not been in that deep to see. There is heavy cloth inside the hull, and I see no need to play with that. I'll get some more pictures posted soon. Other projects this winter will be repair of the seats under the traveler (recore) and strengthening the forward bulkhead tabbing.

A couple links

Here is where I plan to get new balsa core for the seats under the traveler (the klegecel has turned to soup):
http://www.jamestowndistributors.com/product.jsp?process=checkout&part=33054

and a source for low temp epoxy:
http://www.epoxyproducts.com/1_marineresins.html