News & Progress Part 4

12 Nov 2007

 

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31 Oct 07. Fairing and Sanding.          
Faired out the 1st coat on the chainplates and then mixed up and spread more compound on. Then continued with sanding the primer paint. Aft deck and both aft quarters are now sanded. For fun break I cut out the plywood for the electric panel. 

Today we have 1900 hours into the build.

See Oct pics.

30 Oct 07. Sanding!          
Got the fairing compound on the starboard side carbon and a coat of epoxy on the jockey pole holes and the mast partner plywood. Then stared on sanding the decks.
29 Oct 07. More ferrets.           
Around the mast partners and started with fairing in the chain plates.
25 Oct 07. Mast Partners.          
Since I had all the vacuum bag stuff out, I made up the plywood pieces for the mast partners at the deck. Then epoxied it in place and used the vacuum bag to clamp it down.
24 Oct 07. Same thing for the other side.          
Pulled all the vacuum bag stuff off the port side then moved over to the starboard side and got all the carbon on and in the bag.
23 Oct 07. Carbon Chainplates.          
Have not had much time this past couple of weeks just an hour here and there. Got all the prep work done for the carbon chain plates and sanded the area good. Today I laid up the carbon for the port side and got it in the vacuum bag.

See Oct pics.

12 Oct 07. A bit of this and that.           
Sanded the backside of the doublers for the jockey poles. Made up a solid doublers for the bottom of the jockey pole holes and epoxied in place. Then cut the slots for the carbon chain plates.
08 Oct 07. Still plugging away.          
At the jockey pole sockets. Finished with all the plywood doublers the other day. So today I sanded on the inside of the holes and adding fillets to the doublers.

See Oct pics.

01 Oct 07. Scott's first sail!          
Scott McClintock (on the right) finished his Rio Hondo 40 and we launched and took it on it's first sail today. It's a 40 foot trailer-able sail boat. After about a 1/2 hour to untie and set up the mast is was ready to go in the water. It launched with out problems and after maybe 10 minutes to put the rudder in the cassette and power down the keel, we were off. It sailed very well in the light breeze and had a good turn of speed. Well done Scott and congratulations!

See pictures here.

26 Sep 07. Doublers for the holes.          
Cut the holes in the installed doublers and then epoxied 3 more pieces in place. I can only put 3 or 4 in place at a time because the hole saw will not cut any deeper then that at once.
25 Sep 07. Jockey pole holes.          
Drilled the holes for the jockey poles today, including cutting the slot in the bulkhead. Then cut the plywood for the doublers on the inside. Epoxied the 1st 4 layers of doublers.
20 Sep 07. Chain plate fillets          
Filleted between the base and the tube for the chain plates. Also started to layout the holes for the jockey pole until I realized I did not have the right size hole saw.
19 Sep 07. Starting on the chain plates.          
Measured, measured, measured and measured again for the location of the carbon chain plates. Then made up a base and epoxied it and the tube in place.
18 Sep 07. Paint it again.          
One gallon later, I got about 3 coats of paint on the topsides.

See Sep Pix.

17 Sep 07. Sand it off.          
Sanded the primer coat.
14 Sep 07. Paint it white.          
Started with the primer paint on the decks today. Got on the 1st coat of what I'm sure will be many.
13 Sep 07. Sanding.          
Sanded all the fairets today. Vacuumed up the mess and then wiped it all down. Covered the toe rails with a coat of epoxy.
12 Sep 07. Toe rails.          
Got the toe rails epoxied in place. Coined a new term today. When your making fillets with fairing compound, it is a fairet. The fairets were put on around the rails. Also the last bit of fairets on the aft deck.

See Sep Pix.

03-06 Sep 07. La Rochelle France!          
We have been in La Rochelle France for the measurement session, before the start of the Transat 6.50. We apprenticed with the measurers from Classe Mini, David, Alain and Daniel. We checked over 15 boats for stability. We all worked hard but had a great time and I learned much. We met many of the skippers and saw all the boats.

Pix from France

27 Aug 07. Cockpit fairing.          
Faired around the cockpit this morning.
26 Aug 07. Toe rails          
Faired along the cabin sides and deck. Then figured out where the rails & stanchions will go. Then figured out how long and where the toe rails will be. Cut and sanded the toe rails and made a grab handle for just inside the main hatch. Epoxied that and the cockpit toe rail in place.
25 Aug 07. Sick of sanding.           
Ok, I'm not sick of sanding, but I have been sanding and I've been sick. Lost a bunch of work days to a summer cold. All of the decks are now sanded.
14 Aug 07. Well that didn't work!          
When I pulled up the plastic some of the not holes came up with it. This did make a good non skid, and easy on the feet. Just the not holes were too small a diameter to stick well and were too tall, so they broke off too easy. If I could find some plastic with the holes about 1/4" in dia and only about 1/16" thick, then it might work. Oh well, back to mixing grit it with the deck paint.

I knocked off all the not holes and then sand area smooth. Mixed up more fairing bog and got the seat edges and along the shear.

See Aug Pix.

13 Aug 07. Epoxy and an experiment.          
Got the last of the fiberglass on and the final epoxy coat on the boat. Decided to try out an idea for deck non skid. Epoxy and cab-o-sil squeegeed on to a plastic sheet with holes drilled in it.  Then vacuum bagged to hold it down.
09 Aug 07. A bit more glass.          
Epoxied the fiberglass on the cockpit deck today.
08 Aug 07. Back to 'glassing.           
Got more of the thin fiberglass this morning, so I was saved from sanding yesterdays fairing compound. Epoxied on the glass to both cockpit seats and sides and the 2 pie shaped sections by the bow.
07 Aug 07 A bit of everything.          
Sanded the inside of the cabin and gave it a second coat of paint. Sanded the fairing on the shear and added some more fairing. Sanded and put on fairing goop on the cabin top edges.
06 Aug 07. Poxy.        
Put a coat of epoxy on the glass covered parts of the deck and cabin top. Then started to fair the shear.

See Aug Pix.

02 Aug 07. A bit more glass.          
Trimmed up the edges of the fiberglass along the cabintop and sides. Epoxied a couple of small pieces on the back deck and under the cabin hatch. Used up the last of the thin fiberglass and had to order more for the cockpit.
01 Aug 07. More glass.         
Put on the light fiberglass on the cabin sides and both side decks.
31 Jul 07. Glass on.          
Started with the light fiberglass on the decks today. Got the center section from the bow to the aft edge of the cabin top epoxied on.
27 Jul 07. Paint and Kevlar.       
Finished with the 1st coat of paint on the inside of the boat today. Then epoxied a layer of Kevlar tape on the sheer line. This was not in the plans but something I added to help with my encounters with the dock.

See July Pix.

26 Jul 07. Paint and Sanding and Taping.           
Painted back to bulkhead #6. Then sanded on the cabin top and cockpit seats to prep for fiberglass tape. Got those epoxied in place and then sanded the rest of the decks. Had to use the new sander.
25 Jul 07. Paint and San.......?          
Painted the inside on both sides of bulkhead #4. Started to sand the decks when my trusty sander died. Seems like the variable speed controller quit. I may be able to rewire it to bypass the controller, but I decided I have a lot more sanding to do, so I bought a new one.
21 Jul 07. Paint and Epoxy.          
More paint on the inside of the hull, this time the section by the foredeck hatch and part by the daggerboard box. Then rollered on the first coat of epoxy on the outside.

See July Pix.

20 Jul 07. Just sanding.          
Sanded the fairing compound on the inside and the parts on the deck covered yesterday. Also sanded the corners of the cabin top, main hatch and aft decks.
19 Jul 07. Fair and sand.          
Mixed up a bunch of batches of fairing compound and smeared it on the fiberglass tapes on the inside of the boat. Also got some of the missed screw holes  and some of the low spots around the deck. Then sanded the cabin top deck.
15 Jul 07. Paint and sand.          
Finished painting under the cockpit seats today. Then moved to the bow and painted there. Then sanded the starboard side decks and cockpit.
13 & 14 Jul 07. Paint & sand.          
Here is a shot of the underside of the cockpit seat/deck after painting. Most of the area aft of the main hatch is painted. And the deck has been sanded on the port side.

See July Pix.

09 Jul 07. Paint and sand.          
Started to paint inside under the cockpit today. Arms and back gave out before the paint did. At this rate it will take many days. Then to work out the kinks I sanded the deck.  Got the foredeck rough sanded. Also cut a notch in the bow for the forestay fitting.
08 Jul 07. Covered in epoxy.          
Both me and the inside of the boat. All of the undersides of the deck and cabin top are coated with epoxy. Took most of the day and I had to use pie pans to dump the epoxy in too keep it from going off too soon.

Today we now have 1700 hours in to the build!

07 Jul 07. Glass tapes.          
Got all of the fiberglass tapes on the inside cabin top to deck seam. What a pain, an outside 90 deg corner, with gravity working against it. Would get it in place then one end would fall off, then the other, then I'd be holding the ends up and the middle would drop off. Lots of sailor language used. I found that it was better to have too much epoxy on the tapes then too little.
03 Jul 07. More Sanding.          
Finished with the inside sanding. Then vacuumed the interior of the boat. After that is where the picture comes in. If you can imagine the back side of the cockpit seats, the angled part along the glue edge, needed two layers of fiberglass tape. After worming my way back in there with epoxy and the glass tape, many times, I could not make myself go in there to take pictures.
02 Jul 07. Sanding.         
  No pictures today as I spent the entire day sanding the underside of the decks and cabin top.
01 Jul 07. The pox returns!          
A few more fillets around the main hatch and on the inside of the chainplate doublers. Then filled the holes on the cabin top and deck.

See July Pix.

27 Jun 07. Sanding & Filets.          
Sanded the shear caps today. Got all the fillets on the inside of the main hatch.
26 Jun 07. Big things in big trucks.        
Our mast arrived from Forte today! Unpacked it all then moved the mast around to the side yard and hung it from the eves. Oh yeah, got some things done on the boat today. Made up the triangle doublers for the main hatch and epoxied them in place. Them out came the hand planes and I trimmed the shear caps.

See June Pix.

 25 Jun 07 Summer is here!         
Time to keep the epoxy in a cup of ice water. It was 100 deg today in the shop and had on batch of epoxy go off way to soon. Made up the last doublers for the main hatch and glued them in. Then attached the shear cap plywood on both sides of the boat.
21 Jun 07. More of the main hatch.          
Made doublers for the main hatch and epoxied them in with the upper triangles. Fired up the table saw and ripped a bunch of 9mm plywood for the shear cap.
20 Jun 07. Doublers and hatches.        
Made up doublers for the chain plates. Two 6mm ply with a layer of carbon fiber between them. Epoxied them in place and after modifying some of the bar clamps to push, rather then clamp. Also epoxied in the hatch plywood.
19 Jun 07. Cut'n 'n Sand'n.          
Made up the cap pieces on the hull at the aft deck. Epoxied those in place. Sanded the foredeck hatch wedges level. Also sanded the stringers back with a more rounded shape. Did the same on the cabin portlights. Cut some doublers for the main hatch as well as cutting the opening. Screwed that up, as I made the corners square instead of rounded. I think can fix that after the doublers are glued on.

Heard from Classe Mini today, our hull number is USA 693! Now just have to figure out a name.

15 Jun 07. A visitor and a bunch of odds and ends.          
Dan Ohms from Bellingham WA stopped by for a visit. He was promptly put to work.

Made up some wedges for the foredeck hatch, so it will sit level. Trimmed the stringers at the cabin side portlights. Trimmed the deck at the shear clamp. Planed it smooth, thanks Dan! Trimmed the aft hull at the back deck and made up stringers then fitted the inside skin. Epoxied all that together. Fitted the main cabin hatch bulkhead.

See June Pix.

14 Jun 07. Finally Finished Fillets!          
Finished with all the interior fillets today. Yeah! Cut the holes for the port lights in the cabin sides. Made and glued in doublers for the 3 hatches.
13 Jun 07. A hatch and fillets.          
We're back from Newport after sending the Mini's off to Bermuda. We are more energized to work on our boat then ever.

Cut the hole for the foredeck hatch today. It was more to get air flow then any thing else. Then continued to fillet. Fun!

07 Jun 07. A Trip to the Mast Maker.          
Today we visited Forte and saw our mast and other round carbon bits. Our bow sprit was in the machine and getting the final laminations. The mast looks great and after sanding and clear coating, it will be shipped soon. All the people there were  knowledgeable and  very willing to help.

See June Pix.

05 Jun 07. 8 mini's in Newport.           
  All 8 Minis are in Newport for the start of the Bermuda 1-2! Last minute preparation in underway with measuring scheduled for today.
02 Jun 07. A Few More Fillets.           
  Got in a few more fillets today. We are off to Newport for the start of the Bermuda 1-2, with 8 Mini's racing. The 1st Mini race in the USA! Will try to bring news from there.
01 Jun 07. Field Trip Friday.          
Made a visit to Scott McClintock's  shop to see how he is doing on his Rio Hondo 40. He has painted the topsides and is installing the deck hardware. And other then being slowed by a broken hand it is moving along well. Looks great!

See June Pix.

01 Jun 07. Fillet Friday.          
Fillets today. One on top of the deck where the cabin top and foredeck meet. And the rest inside where the bulkheads and top skin meet.
28 May 07. Roofed.            
Pulled the screws from the cabin top skin. Found that where I had piled the anchor yesterday was just not enough weight. Needed to re-epoxy that section and pull it down with clamps. Trimmed the top skin with sides. We got a cabin!

Last week we went over 1600 mhrs.

27 May 07. Cabin top skin.          
Fitted the cabin top skin and epoxied it in place today.

May Pix.

26 May 07. Fillets and shaving doublers.         
Put down the fillets along the deck to cabin sides. Then got out my trusty hand plane and trimmed the doublers flush.
22 May 07. Cabin sides.          
Trimmed the cabin top doublers where they meet the sides. Scarfed the forward and aft sides then epoxied them in place.

As for the wet box, it just popped right out. Ha! Yeah right! After much prying, wiggling, jamming wedges in, and lots of  cursing, it was still stuck in the mould. So out came the saw, hammer and pry bar. The mould was soon cut to bits and the wet box emerged, looking good and more importantly, fitting.

May Pix.

21 May 07. Wet box laid up.          
Got up at the crack of dawn, before it got too hot, and finally laid up the wet box. We'll see if it will come out of the mould tomorrow. Took a break and then filleted under all the cabin top doublers.
20 May 07. Clean up.          
  Just cleaned up the dripped epoxy under the cabin top doublers today. No pix.
16 May 07. Doubler fun.          
Fitted all the 9mm ply for the cabin top doublers. Then epoxied them all in place. It's hot here and I made the 2nd batch of epoxy too large, it went off in the cup. 1st time in a long time for that.

May Pix.

15 May 07. Cabin top.           
Added the bottom part of the hatch triangles. Filleted around the aft cabin top section. Rough cut the 9mm plywood for the cabin top doublers. Fitted the doublers on the center line. Trimmed the cabin side stringers.
14 May 09. The last piece of plywood!          
Cut out the last piece of plywood for the cabin top. Sort of fit the cabin top skins in place to find where the top ends at the aft end. Trimmed the stringers to this point and glued on the aft cabin ends.

I pulled all the plastic from the wet box mould and lined it with packing tape, a tip from Drew. Thanks Drew! Still waiting for the release liquid as well.

10 May 09. Cutting carbon.          
And Kevlar for the wet box. Tried lining the box with plastic film so the epoxy will not stick. That was a pain and did not turn out like I wanted. So I ordered a liquid release. We'll see.

May Pix.

Antigua Sailing Week!          
We had a great time at Antigua Sailing Week, great wind, warm water, good racing. Made many new friends and finished 8th in our fleet for the week.

More Antigua Photos here.

Photo by Tim Wright.

25 Apr 07. Fairing the box.           
Rounded off the corners, faired the insides of the box and got one coat of epoxy on.

We are off to Antigua Sailing Week to race an Oceanis 42, "Mana" with a group from our club. Wish us luck!

23 Apr 07. Assembling the wet box box.           
Screwed the wet box mold together and glued on the top edge reinforcements.
20 Apr 07. Starting on the wet box.          
Cleaned things up today then started in on making the keel wet box. This will also be made of carbon fiber. The first thing we have to do is make the mold for laying up the wet box. Got most of the wood cut for the mold.
17 Apr 07. Unwrapping the keel.          
Took the keel strut out of the vacuum bag and pulled off the peal ply. It looks good and will now go in to the "post cure oven", the attic.
16 Apr 07. Keel is kovered!          
Got all of the keel skin on today. 3 layers of carbon uni's in the axel area, one full length layer of uni. Then 3 layers of carbon fabric and one of Kevlar. And maybe used about 3/4 of a gallon of epoxy.

See Apr Pix.

15 Apr 07. Cutting Carbon.          
Cut all the carbon fiber and Kevlar that we'll need for the skin of the keel. Made a pattern from plastic to help with getting the right rough cut.  Then laid out more plastic and sandwiched the cut carbon in between, ready for wetting out.
11 Apr 07. Final fairing.           
Sanded and filled the last of the low spots on the keel.
10 Apr 07. Keel Fairing.          
Faired the keel blade today. Just like riding a bicycle, some skills just will not go away. After the fairing I epoxied on the trailing edge section.

See Apr Pix.

09 Apr 07. Keel assembly.          
Cleaned up the holes for the G-10 tube that the axel will slide into. Then epoxied all but the trailing edge section together. The bulb plate was aligned and epoxied in as well.
08 Apr 07. Happy Easter, holey keel.         
Profiled the last section and aligned the slot for the bulb plate. Drilled the holes for the axel shaft.
05 Apr 07. More profiling.           
Got three more sections profiled yesterday and today. Found that even with a new blade the band saw does not like going though two 3mm thick carbon fiber and 75mm of foam. So out with my trusty saber saw and it made quick work of it. Maybe not as neat, but it will work.
03 Apr 07. Started the keel profile.         
Cut a shallow slot on the leading edge and bonded in a 5mm round carbon fiber rod to help define the leading edge. Continued with sanding the carbon lay-ups until late in the day when the UPS guy showed up with the new band saw blades. So I trimmed the leading edge to a rough profile.

See Apr Pix.

29 Mar 07. Last khunk of keel.          
Laid up and in the bag. The other four are on the table to the right. Started to trim the profile on the leading edge section. I got most of the one side cut when the band saw blade gave out. They don't make $99 band saws like they use to. So I started to "clean up" the edges of the carbon on the keel sections. Clean is not the word to use when sanding carbon!
28 Mar 07. More of the komposite keel.          
Two more keel sections laid up and in the vacuum bag.

Today at about 3:00 pm, we went over 1500 build hours.

27 Mar 07. Kontinuing with the keel.         
Cut the relief in the foam for the axle reinforcements. Got two of the sections laminated and the lengthwise strips of carbon fiber epoxied on.  
23 Keel cut out.          
Released the carbon plate from the vacuum bag. Easier said then done. Cut it to size and cut the stiffener strips, then epoxied them on. Cut the keel sections to match the plans. And then glued on the last bits of foam to the keel. 

See Mar Pix.

22 Mar 07. Carbon pile....          
.... and a bit of Kevlar. Raining in Phoenix today, so I moved on to making the 10mm thick plate that the lead bulb will bolt to. 14 layers of C/F and 2 of Kevlar. All covered with epoxy and vacuum bagged. Started to lay out the keel plan form but needed to trim the edges and with the rain did not have room to make the cuts. Maybe tomorrow?
21 Mar 07. Two at a time.           
Got the last two keel sections laid up and under vacuum today. Also laminated the trailing edge section at and above the axel, the old fashioned way, with clamps.
18 Mar 07. Half a keel.          
Released the keel section from the bag and then cut the rest of the carbon fiber we'll need to laminate the last 2 sections.
17 Mar 07. Happy St. Patrick's Day!          
If you look closely the release plastic is green. Laid up another section of the keel. We are trying vacuum bagging a new way. Bagging to the work table. Other then a new learning curve it seems to be do well, pulling 19 inHg. Thanks Katie and Drew.

See Mar Pix.

16 Mar 07. Well that came out ok.         
That is the trailing edge piece of the keel strut. So we then laid up another section. And as for getting a jump on the epoxy lay ups before it gets too hot, well it was a new record for Phoenix today, 99 deg.
15 Mar 07. Carbon for the keel.          
Have been busy the last week with other things and have had only an hour or so every couple of days to get things done. Made up a bunch of test samples to find just how many layers of carbon fiber I'll need to get the thickness required. Also rearranged the shop to get a long work table for the keel lay up. Laid up a single thin piece of carbon fiber to be used along the trailing edge. This turned out to not work at all. It came out of the bag wrinkled and the cracked as the peel ply was pulled off. So I laminated the C/F between the foam for the trailing edge. We'll see tomorrow how it comes out.
05 Mar 07. On to something new....          
...before it gets to hot. Removed all the screws and cleaned up the foredeck and side decks. I've decided to lay-up the keel strut while it is still cool and there is time to wet out the carbon fiber. So with that in mind I rough cut all the foam for the strut today.
 04 Mar 07. Deck celebration.         
Epoxied the foredeck and side decks on today.

 

See Mar Pix.

 03 Mar 07. More scarf'n.         
Scarfed the foredeck and side deck skins today. Even did the long scarf down the centerline on the foredeck skins. Much worrying for nothing as it was not much harder the the other scarfs.  Drilled the pilot holes for screwing the decks down and got every thing ready to put on the skin.
          
   
          
   
          
   
    News & Progress Part 3

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