News & Progress Part Three.             04-Mar-07

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28 Feb 07. Undersides.         
Of the foredeck and side deck skins are covered with the 1st coat of epoxy.
27 Feb 07. Trimmed up.          
Removed the screws and trimmed the aft deck skin along the cockpit edge. Then spent some time fitting the side deck and foredeck skins. Marked all the stringers on the skins.
26 Feb 07. A place to sit.          
Trimmed the deck stringers aft of bulkhead #2 so the deck skin would lay flat. Then scarfed the plywood for the aft side decks. Scarfed all 4 pieces of plywood at the time. Slopped on the epoxy and screwed down the aft deck skins.

See Feb Pix.

22 Feb 07. Oh those fillets.          
What fun they are! Ok back to reality. Put another coat of epoxy on the side deck skins. Then started the fillets on what I've installed so far. The aft water tanks, inside are done. No pictures as I can not get the camera in the deck plate hole. Can just about get my arm in, can't even see how it looks. Will have to wait until the fillets harden and feel if I missed any spots. The picture shows frame 9 & 8 with the fillets along the frames and the cockpit floor.
21 Feb 07. Trimming the seat edge.           
Trimmed the seat edge plywood even with the side deck. Fitted the side deck skin and marked the underside for the epoxy covering and then put on a coat of epoxy. Filleted the cockpit corners.
20 Feb 07. Wired!          
Cleaned up and trimmed the cockpit side skin, then epoxied in the seat edge plywood. Glued down the cockpit corner stringer. Laid out the side deck skins.
19 Feb 07. Cockpit sides.          
The elves were busy again this week, all the inside hatches are finished and in place. The deck screws were also pulled. So I filleted around the aft deck edges and some of the underside. Then I cut, fitted and epoxied in the cockpit sides.

See Feb Pix.

16 Feb 07. Aft decks    .      
Epoxied the aft decks on today.
15 Feb 07. Decked!          
Scarfed the cockpit deck skin and the back deck plywood. Then epoxied the cockpit deck in place. Cut the holes for the access plates in the back deck. Made the doublers and glued them in as well. Finished with relieving the hatch latches  and gave them a final coat of epoxy/graphite.
09 Feb 07. Latches for hatches.          
This is the last of the latches for the bunktop hatches. Epoxied them in place and got a second coat of epoxy on the deck skins. Logged in a total of 1400 man hours today.
08 Feb 07. If you have a hatch you need a _______ ?          
Hole.

Cut the hole for the escape hatch today. And other then having to find a new technique for getting the saw around the corners, all went well. The latches came off the hatch with just a bit of persuasion and after triming the edge down,  they work fine and lay flat! Also coated the underside of the cockpit deck with epoxy.

See Feb Pix.

07 Feb 07. A hatch of a different color.          
Received all the hatches from Mauri Pro Sailing this week. 1 foredeck, 1 main and the escape hatch, along with 2 portlights. The boat elves made a visit and cut all the bunk top hatch latch parts. Made a drilling guide and drilled all the finger holes in the latch sliders. Epoxied a handful together. Tomorrow we find out if this idea will work.
04 Feb 07. Still with the hatches.          
Got a second coat of epoxy on all the hatches. Same with the latches with the graphite mix.
03 Feb 07. On to the other side.          
Flipped the hatches over and after a bit of clean up I coated the top side. Mixed a batch of epoxy with graphite powder and slapped it on the latch parts.
02 Feb 07. More epoxy on the hatches.           
  No pictures. Just covered all the hatches with another coat of epoxy. If you what to see what it looks like just look at yesterdays pix. Got a coat on the cockpit floor stringers as well.
01 Feb 07. Again with the hatches.          
Ripped the strips that will be used to hold in the latches. Then coated all the hatches with epoxy.

See Feb Pix.

26 Jan 07. More fun with hatches.          
Worked on the bunk hatches today. Made a router guide and cut the slots for the latches. Then trimmed down the catches and epoxied them in place. Also made and epoxied in an additional cockpit doubler for where the tiller is attached. 
22 Jan 07. Odd and ends.           
Finished epoxying the hatch doublers on today and filleted under the cockpit deck doublers. Fitted the aft deck and marked for scarfing.
20 Jan 07. Cold and wet here in Phoenix...          
...so I got out the saw and cut things off. 

Trimmed the transom ends on both sides. This is needed to make room for the aft deck skin. Sanded the bunk lid doublers and epoxied them to 8 of the hatches. Also epoxied in the cockpit floor doubler. Hopefully the heater will keep the garage warm enough for the epoxy to work.

See Jan Pix.

16 Jan 07. Too cold here!          
Today the shop only got to 53 deg. Warmest it has been since Sat. Our club had it's big race this past weekend with almost 90 boats. Sundays race was postponed for 2 hours due to the cold. The low at the lake was 24 deg and never got above 45 that day. Too cold for us warm-blooded desert dwellers.

Since it was too cold for the epoxy I just cut things out. Cut the doubler for the cockpit, fit the cockpit deck and marked the lines for the stringers. Then cut most of the bits for the bunk hatch locks. 

10 Jan 07. Doublers and deck skin and stringers and...           
Today was a do a bit of every thing day. Faired the deck doublers that were in place. Then I needed to more define just where the cabin aft end was, so I cut out most of the deck and cockpit skin. After determining the aft end of the cabin, I cut and fit the doublers for that area and the doublers for the aft edge of the cockpit seats where the traveler will mount. Epoxied in the cockpit floor stringers and the deck doublers.

See Jan Pix.

09 Jan 07. More fun with fillets.           
  No pictures for today. Filleted on the inside of all the deck doublers.
08 Jan 07. Double up.           
Mike Smith and his wife Jen from Connecticut stopped by for visit. He is building another Dudley Dix design, a Cape Henry 21. See his web site here.

Trimmed and sanded the bow blocks for the forestay fitting bolts. Drilled holes in the bulkheads for the wiring. Then epoxied in the rest of the deck doublers.

04 Jan 07. Shear trim.          
Planed and sanded the hull skin smooth to the shear clamp. Also faired the top edge of the shear clamp to the side decks. Got a few of the deck doublers epoxied in place. 

There is something satisfying in using a hand plane to bring a piece of wood to the final shape that just is not there using a power sander.

03 Jan 07.  Cutting off the hull.        
Trimmed the hull at the shear clamp today. Went well once I figured out how to hold the saw to the hull with base canted at 45. Trimmed the bow plank where it stuck up. Also got another coat of epoxy on the D/B box.
02 Jan 07. Happy new year!          
Trimmed off the corners on the rest of the shear clamp and then fitted all the deck doublers. Gave the D/B box a once over with the sander and then coated it with epoxy.

See Jan Pix.

29 Dec 06. Deck doublers.           
The sun came out today and warmed things enough to repair the rub rail on Craig's boat. Cleaned up the messes we made yesterday and redid the gelcoat dings.

I then mixed up fillet stuff and went to work on the bunk top next to the D/B box. Then started in on the deck doublers. Laid out all the pieces Sam had cut and then fit two of them. The outboard doublers are up against the sheer clamp, which comes to a point at that side. I decided to trim off about a 5mm edge to make a flat surface for the deck doublers.

See Dec Pix.

28 Dec 06. Craig's boat.          
Worked on our long time crewmember Craig's boat today. His boat was damaged during a dust storm this summer. The wind had picked up his boat and trailer and laid them over on the starboard side. Besides the rudder being damaged, it also broke the mast and compression post, broke out the side window and pulled loose the rub rail.

Today we fitted a new compression post, reseated a bulkhead, fitted the repaired rudder, replaced the side window and filled in the various gelcoat dings. It was cold and rainy all day and we learned that the gelcoat repair gook does not like to be rained on before it sets up.

27 Dec 06. Odds and ends.          
Did a bunch of little jobs today. Ripped a plank of African Mahogany and epoxied them together to make a compression post for Craig's boat. Then filled in the spaces forward and aft of the D/B box. Glued down the last of the fwd bunk top next to the box. Fit, cut and epoxied the aft deck stringers.
23 Dec 06. Trimmed the stringers.          
Trimmed the stringers by the cabin front. Re-glued the 2 small stringers in the bow and dumped epoxy cab-o-sil mix in around the D/B box.
22 Dec 06. A gift from Samta Clausmus.           
It's a 4x8 sheet of 9mm plywood. And like all good Christmas gifts, some assembly required. Thanks Sam!

Epoxied in the daggerboard box today. Somehow all the dry fitting of the parts for a snug fit, turned into a tight fit on some parts and loose on others. Maybe because it is cold and raining here? After  mess was made with the epoxy and much cursing, it was in. I then glued in the  rest of the cabin top stringers.

See Dec Pix.

21 Dec 06. Paint it black.          
Well not paint but epoxy and graphite powder. This should make for a smooth and slick surface on the inside of the D/B box.  It is cold here and this epoxy coat took forever to set up, even with the heater going. While waiting I cut and fitted a couple of stringer pieces in the forward deck. Cleaned out the rest of the stringer notches. I also shot the final coat of paint on Craig's rudder. I had some of the VC Perf paint left over so I tried an experiment in tinting it orange. Well by the time i got the right color, things were starting to separate. I put some on the daggerboard and on a test panel. we'll see how it looks when it dries.
17 Dec 06. Sanding, deck stringers and paint.          
Sanded the daggerboard and rudder. Then went though all the stringer wood and rough cut the rest of the deck stringers. They are in about where they'll go. I then put on more primer on the D/B and VC Perf on the rudder.
16 Dec 06. Epoxy, paint and paint.          
Epoxied the daggerboard box again, painted the daggerboard with primmer and painted Craig's rudder with VC Perf. Used a real sprayer for the rudder this time. Seemed to go on very well. We'll see tomorrow when it is time to sand. Also took off the clamps from the stringers and trimmed the ends. 
15 Dec 06. Deck stringers.          
Covered the inside of the daggerboard box with epoxy. Then cut and fit the outboard two deck stringers. Epoxied the bow centerline stringer and the deck stringers in place.

See Dec Pix.

11 Dec 06. Assembling the daggerboard box.          
Cut and fitted all the little parts for the daggerboard box, mostly the doublers and reinforcements at the hull. Then epoxied the front and back ends to the one side. 
10 Dec 06. Ready for the party.          
The "Deck the Hull" party. Cleaned all the sanding dust out of the insides and prettied it up. Thanks to all who came!
09 Dec 06. Hole in the bottom of the mini!          
Cut the slot for the daggerboard in the bottom of the boat today. Other than dulling a new saw blade all went well. Then cut and dry fit the daggerboard box. I also could not let a day go by without sanding some on the daggerboard.

See Dec Pix.

05 Dec 06. A couple of deck stringers.          
Sanded on both the daggerboard and rudder today. A lot of sanding on the rudder, as yesterday I shot the VC paint with "disposable" sprayers. The prevail sprayer was very very slow and ran out of juice with about 1/2 the paint left. So I then used a aerosol can that runs on a shot of compressed air. That was a big mistake. That thing would not spray a mist no mater what nozzle I tried. Looks like I'll be needing a real sprayer for xmas. Stared cutting and fitting the plywood for the daggerboard box when I needed to define just where it would be at the deck. So I epoxied in the two center deck stringers. Also scooted the boat out side to see how the daggerboard fits.
04 Dec 06. More sanding and painting.          
Sanded both the daggerboard and Craig's rudder. Then worked on the doubler for the daggerboard hull exit. That is what has been driving me to finish the daggerboard. Got is shaped to fit the hull and the slot cut, then epoxied it in place. Put down more primer on the daggerboard and then painted Craig's rudder with the VC Performance bottom paint.
27 Nov 06. Shaped and sanded.           
And the 1st coat of primer. Sanded off almost all the fairing compound to make a good trailing edge. Gave it one last all over sanding and put on the 1st coat of primer. Also did the final sanding on one side of Craig's rudder and flipped it over and primmered the other side.
22 Nov 06. Great gobs of.......          
....fairing compound. I'm trying to build up the last bit on the trailing edge. I figure that about 95% of this will end up as dust. The leading edge was sanded along with Craig's rudder. Painted a 2nd coat on the rudder and parts of the inside of the hull.
21 Nov 06. More painting.          
Sanded the daggerboard and Craig's rudder. Then made up a batch of epoxy and Cab-o-Sil and put it on the leading edge of the daggerboard. That is a stronger mix then the fairing goop I have been using. It will be harder to sand but will handle bumps better. I then finished painting the aft section of the insides.

See Nov pix.

17 Nov 06. Disaster strikes!           
That's right disaster! Not sure how or when it happened, but my "favorite" longboard broke. All is not lost as I was able to epoxy it back together. Hopefully it will work better then when new. Sanded the daggerboard and had just a few areas to fill. Then continued with the painting of the bilge area.
16 Nov 06. Take off, put it back on.          
Sanded the daggerboard and then added more fairing mix. It seems to be getting fairly close. I hope. Then I painted the bilge area with epoxy paint.
15 Nov 06. Daggerboard fairing.          
Sanded and slapped on more fairing goop. It may be getting close. Also used the leftover goop to make repairs to our longtime J/24 crew member Craig's rudder. It was damaged late this summer during a microburst that picked up his boat and trailer and slammed it down on it's side. In addition to the rudder his mast was bent and busted out the cabin window.
10 Nov 06. More ridges on the daggerboard.          
Faired the daggerboard again. Found a flat spot down the center. So mix up more microballoons and epoxy and lay it down with the notched putty knife. While waiting for that to kick, I put down the 2nd coat of epoxy on the area around the keel box.
09 Nov 06. Mast step and daggerboard.         
The other night I had time after work to epoxy in the top of the mast step. So today I sanded the area and put down a layer of carbon fiber. I then coated all the areas around the keel box that needed the first coat of epoxy.

I then sanded the daggerboard, the ridges worked as advertised. Mixed up fairing compound and filled in all the gaps between the ridges.

05 Nov 06. Mast step.          
Epoxied in the mast step wood and foam support pieces. 
04 Nov 06. Mini Meeting.          
We attended the annual meeting of the Mini Class U.S. in Newport, RI. We had a great time and it was fun putting faces with all our email friends. 

We then went on a field trip to Drew & Katie's mini and Joe Cooper's "old school" mini, which is in the middle of a refit.

See Nov pix.

30 Oct 06. Mast Step.          
Cut and fitted all the bits for the mast step. Plywood for most of it and foam for the voids.

Today we went over 1200 hours.

See Oct pix.

19 Oct 06. And more carbon.           
Added the last of the carbon fiber to the mast/keel area, along the aft side of bulkhead #4. This is to add extra strength to the mast step area.
18 Oct 06. More carbon and a visit from an old friend.            
Laid down the CF in the center section of the keel area. And started more fairing of the daggerboard. Who was the old friend? It was the longboard! Look at the dust on the floor! Also the foil shaped sanding board seems to be working ok. Unfortunately the one I built for the leading edge just jams into surface and does not sand well.
17 Oct 06. More carbon.           
Added the fore and aft carbon fiber strips on both side of the keel area.
13 Oct 06. Continuing keel reinforcement.           
Finished with the athwart ship CF reinforcement. The peel-ply came off easily and left a good surface.
12 Oct 06. Keel area reinforcement.           
Started adding the strips of carbon fiber for the keel area. Had to sand and clean the area first. The white stuff in the pictures is peel-ply. It should come right off after the epoxy sets and leave a surface good for the next layer without sanding.
11 Oct 06. One of Sam's 3 project days.           
Installed the 4 hatches on the water ballast tanks and screwed down the crash bullhead hatch. Built the stiffeners for the single point lift on the backbone and epoxied them in with carbon fiber. Laid out the daggerboard foil shape and made sanding boards for the final foil shape faring.

See Oct pix.

10 Oct 06. Sealed and grooved.           
Got the neoprene seals on the water tank and #1 hatches. Flipped the daggerboard over and put down a layer of grooved fairing compound.

 

5-6 Oct 06. Harvest Moon Regatta            
Sailed with Sam Ausmas On his Pogo 1 for the LYC Harvest Moon Regatta. Had a great time and other then falling overboard, I learned more about mini sailing, even though the wind was light for the start and mostly forward of the beam.
29 Sep 06. More visitors.            
Andy Abel, of the mini Zonda USA 632 fame, is in town and stopped by for a visit. Learned a lot more about minis. His web site is here.

I did manage to get some work done today. Put down grooved fairing compound on 1/2 of the fwd daggerboard. And I put a layer of carbon fiber on the fwd side of bulkhead #4 to help reinforce the mast base.

See Sep pix.

25 Sep 06. Hatches.           
Got the 2nd coat of epoxy on the water tank hatches and the final covering on the #1 bulkhead hatch.
24 Sep 06. Epoxied out.           
Finished with the second coat of epoxy on the inside of the boat. With help from Dennis M, who stopped by for a bit of a repair job to his Laser and found himself pressed into painting on epoxy. 
23 Sep 06. We go sailing.           
Sam was worried about all the extra help we'd be getting from Carel, so after I got a few more areas covered with epoxy we headed out to Lake Pleasant for a sail on the J/24. We had a great time and Carel was shown that there is sailing in the desert. 
22 Sep 06. More Epoxy.         
Gave the boat a light scuff sanding and put down the 2nd coat of epoxy. Got the forward part of the boat from bulkhead #5 covered.
20 Sep 06. Build a mini, make friends from all over the world.            
Carel van Driel, from the Netherlands, stopped by for a visit. He's in town on business. He has been building a Dix mini as well. See his website here. We had a great time comparing notes and ideas. I also gave him a hard time for not having his website up to date.
19 Sep 06. Covered in epoxy.          
Not me, the boat. All the interior wood has at least one coat of epoxy on it. Got the fwd bunks and tank tops covered with the thin epoxy.
18 Sep 06. After installing something what do we do next?           
Fillets!

That's right fillets around the water tank tops. Also filled in the "dashed" lines on the tank faces.

17 Sep 06. Tops in tanks.            
Got the tops of the main water ballast tanks epoxied in today. Again had to use creative clamping.

See Sep pix.

16 Sep 06. Tank fittings.           
Installed the rest of the ballast water tank fittings and and got some more epoxy on the hatch lids.
13 Sep 06. Backing plates.           
Got the backing plates on about 1/2 of the screw inserts. Those are the small bits of plywood under the clamps. Should make for a water tight seal. Also got some more epoxy on the lids.
12 Sep 06. Tank lids.           
Drilled the screw holes in the water tank lids. Then knocked out all the inserts that I put in yesterday. Now that all the holes are drilled I have to coat everything with epoxy. So I then put a couple of coats of epoxy. I also routered out and cut all the pieces of 4mm that will go on the back side of the inserts.
10 Sep 06. The boat elves have been at work.           
Came out today to find that the fillets around the fwd bunk are done! Now If I could just teach them to sand. I sanded the fillets and the fwd part of the boat in prep for a 2nd coat of epoxy. Drilled the holes and installed the screw inserts in the #1 bulkhead hatch. Fitted the hatch. Drilled and installed the inserts in the water tank top access lids.

See Sep pix.

06 Sep 06. Everything but the kitchen sink.          
And I would have used it, but it did not weigh enough. Epoxied down the fwd bunk tops today. Had a bit of epoxy left over so I glued on the deck stringer doublers on bulkhead #9. Busted off the old doubler on the bulkhead #1 hatch. Then cut, fitted and epoxied on a new one. Hopefully we will have enough edge distance for the hatch screws.
05 Sep 06. Starboard side compartments.          
All the bunk compartments are painted. Will have to do some touch up tomorrow, but the paint is on. Also got the second coat of epoxy on the underside of the fwd bunk.

See Sep pix.

04 Sep 06. Funs over, back on the bus!          
Well vacation is over and back to work. We visited with Wendy's sister and her family in Seattle. Pix here. We attended the Pacific Seacraft Rendezvous in Port Townsend, WA, and sailed on both a PS Pilot House 40 and a PS 31. We are not ready to go the dark side and get a furniture boat, but we could see where the pilot house would be a great place to be when the weather turns cold and rainy. In looking at details of the Pacific Seacraft, I may have found a solution to the bunk lids problem. 

Oh yea back to work, I got the rest of the port side compartments painted. Rough drew the bulkhead 1 hatch doubler.

See Sep Pix.

19 Aug 06. Mini sailing with Sam.          
We sailed on our 1st mini with Sam in Houston. Raced in their TGIF evening race. Other than the light wind and hot humid temps it was a great time. The day started with thunderstorms in the area but cleared out by race time. A beautiful sunset under spinnaker just set the mini hook deeper. Thanks Sam!
17 Aug 06. A bit more paint.           
Had a bit of time this afternoon so I painted inside 2 of the port bunk compartments. We are off to Houston this weekend to sail with Sam on his Pogo mini in the TGIF race. I Have checked with the TSA and will not be able to bring our longboards with us, as they are considered instruments of torture. We will however be bringing a fresh batch of Arizona rash!
09 Aug 06. A seek preview!          
We took a trip to visit friends in Oriental, North Carolina. While there we took a side trip up the coast to Virginia and visited with Dudley Dix, the designer of our mini, and his wife Delia. We had a great time and he showed us his latest project. A very cool skiff! It is still under development and no plans or kits are available at this time. 

See Aug pix.

01 Aug 06. Paint.          
Painted under the fwd bunk today. Still undecided about painting the inside of the hull sides. It would be less work, but I'm wondering if leaving it "natural" would be to dark? Sure looks good as it is.

Comments or suggestions?

See Aug pix.

 

31 July 06. All covered in epoxy!          
Not me, the inside of the boat. Well ok, some on me as well. The keel area has been left dry so the fiberglass reinforcement, will bond to the wood better.
30 July 06. Coating the insides.          
Started coating the insides with the thin epoxy. Got the insides of the main bunks and about 1/2 of the sides and bottom.
25 & 26 July. Sanding.          
Spent the last two days sanding the interior of the boat, getting ready for a coat of epoxy. When bored with that I drilled the holes in bulkhead #1 hatch and fitted the screw inserts.
24 July 06. Sticky stuff.          
Spent the day epoxying. Stuck on the hatch doublers to the v bunk tops. Covered the insides with thin epoxy fwd of bulkhead #4. Coated the insides of the aft water tanks and then the underside of the v bunk tops. And also my hair.
20 July 06. More Bunk.          
Cut and fitted the tops for the fwd bunk. Also cut the hatches out and made the doublers for the holes. Drilled the holes for the aft water tank fittings. Lots of visual progress today.
19 July 06. Fwd Bunks & Aft Tanks.          
Finished with the supports for the fwd bunk. Warped the side walls of the aft tanks and epoxied them in place.
18 July 06. What the heck is that?          
It is the "holding tool" for the rudder fittings. I wanted to be sure the side wall of the aft water tanks would not interfere with the bolts for the rudder gudgeons. I held this fixture on the inside and marked the hole locations. More pix in the July photos. Finished epoxying in the wood supports for the fwd bunk. Glued in the fwd and bottom edge of the aft tank sides.
14 July 06. More of the aft tanks.          
Epoxied in the fwd parts of the aft water tanks to bulkhead # 9. Rough cut the side panels for the tanks as well. Also rough cut the 9mm plywood we'll need for the forward daggerboard box. Cut and fit the wood supports for the fwd bunk and epoxied about 1/2 of them in. The good side of the high heat here, is the epoxy sets up quick and you can continue working.
13 July 06. Start on the aft tanks          
Epoxied on the fiberglass tape on the fwd bunk support parts. It was 112 deg in Phoenix today and hit 106 deg in the shop. Not a lot of time to work with the epoxy today. Cut and dry fit the fwd parts of the aft water ballast tanks.

See the July pix.

08 July 06. Last of the big fillets!          
The last of the fiberglass covered big fillets, on the single backbone are done. Also got one side of the #1 hatch covered with epoxy.
06 July 06. Thru hull doublers.          
Filleted on the fwd bunk frames and sanded. Built doublers where the thru hulls for the Sofo Scoop and the speed/depth transducers will go. Also built a box around the transducers so any leaks will not flood the boat. I wanted the speed/depth transducer to be on the center line to minimize any heel effects. I hope this location is far enough back from the keel. I did not want it forward of the keel as it may be out of the water at higher speeds! Also cut, fitted and glued on the doubler for the bulkhead #1 hatch.
02 July 06. Paint and bunk.          
Painted the forepeak area and epoxied in the fwd bunk frames. Went over 1000 hours of construction today. Also started a third progress page.

See the July pix.

           The past news can be found here:  News & Progress - Part Two