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Fri Jul 06, 2012 9:17 am

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Posts: 294
Location: Victoria, B.C.

More bulkhead 1 - continued from page 12.


Attachments:
File comment: 1st 2 screws placed (1"). Eventually have 4 screws on each side
P1020513.jpg
P1020513.jpg [ 50.1 KiB | Viewed 366 times ]
File comment: Bulkhead 1 in position. All cleats had their exposed edges rounded on a router table using a 3/8 round-over bit were coated with 3 coats of clear epoxy prior to glue-up. I did not glue bulkhead 1 in place at this point as was too easy to bash about in the tight quarters of the garage. Removed and will glue-up just before adding side planks.
P1020515.jpg
P1020515.jpg [ 36.47 KiB | Viewed 366 times ]

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Fri Jul 06, 2012 9:29 am

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Location: Victoria, B.C.

Glue up - I pre-taped all joints once again. I also screwed and glued the cleats to the stem between bulkheads 2 & 3 and 3 & 4 as well as the vertical cleat to the forward side of bulkhead 4 prior to final attachment of the stem.


Attachments:
File comment: All glue joints were pretreated with straight epoxy, then thickened epoxy as second coat about 1/2 hour later. Screwed stem into vertical cleat previously attached to bulkhead 4
P1020521.jpg
P1020521.jpg [ 43.77 KiB | Viewed 366 times ]
File comment: Cleat between bulkheads 2 & 3. Screws into bottom sheet measured properly this time so do not go all the way through
P1020522.jpg
P1020522.jpg [ 34.09 KiB | Viewed 366 times ]
File comment: Cleat between bulkheads 3 & 4. You can see the rounded edges
P1020523.jpg
P1020523.jpg [ 36.84 KiB | Viewed 366 times ]

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Fri Jul 06, 2012 9:40 am

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Joined: Sat Jan 07, 2012 11:12 am
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Location: Victoria, B.C.

Bulkheads 2 and 3


Attachments:
File comment: Applying thickened epoxy to the bottom of bulkheads 2 & 3
P1020525.jpg
P1020525.jpg [ 40.59 KiB | Viewed 366 times ]
File comment: Bulkheads in place (except #1) and supported by jigs on top (supplied in kit). Note that the cleats to support the sole boards were dry fitted and glued on to bulkhead 3 before it was glued in place
P1020526.jpg
P1020526.jpg [ 45.71 KiB | Viewed 366 times ]
File comment: I also placed the sole board in place between bulkheads 3 & 4 (after packing taping the edges to make sure it did not end up glued down). Clamps were placed between bulkheads 3 & 4 to make sure alignment of #3 correct while epoxy set.
P1020531.jpg
P1020531.jpg [ 40.05 KiB | Viewed 366 times ]

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Fri Jul 06, 2012 9:47 am

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Joined: Sat Jan 07, 2012 11:12 am
Posts: 294
Location: Victoria, B.C.

Fillets done. Placed using the folded freezer bag method. Fillets rounded using my finger.


Attachments:
File comment: Bulkheads 2 & 3
P1020528.jpg
P1020528.jpg [ 49.03 KiB | Viewed 365 times ]
File comment: Stem and bulkhead 2 showing scuppers yet again
P1020529.jpg
P1020529.jpg [ 40.99 KiB | Viewed 365 times ]
File comment: Tape removed. You can see the screw holes on the back of bulkhead 3 for the sole cleats. Filled with thickened epoxy and sanded flush
P1020535.jpg
P1020535.jpg [ 47.16 KiB | Viewed 365 times ]

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Fri Jul 06, 2012 1:30 pm

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Joined: Thu Oct 21, 2010 5:55 am
Posts: 237
Location: Port Ludlow, Washington

Dan, you are doing such a great job I'm jealous. Your fillets are very impressive.
You may have converted me to using tape!

Note to self: Look for good deals on lots of blue tape

I question the need to apply fillets around cleats as shown in photo P1020528 above.

It's cumulatively a lot of extra weight/expense and a fair amount of extra effort to go through. Again, though, keep up the great work. We're all learning a lot from your build documentation. Thanks!

Simeon :D



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Fri Jul 06, 2012 5:07 pm

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Joined: Sat Jan 07, 2012 11:12 am
Posts: 294
Location: Victoria, B.C.

Thanks Simeon,

Any comments on the scuppers cut into bulkhead 2 as shown on the previous page/ I.e. do you think they create any structural issues?

Cheers,

Dan



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Fri Jul 06, 2012 10:24 pm

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Joined: Thu Oct 21, 2010 5:55 am
Posts: 237
Location: Port Ludlow, Washington

Dan, I think they look fine. I don't think there are structural concerns. JW designs a lot of strength margin into his plans. Unless I hear anything to the contrary, I plan to do the same on my build :)

Simeon



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Mon Jul 09, 2012 10:15 am

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Joined: Sat Jan 07, 2012 11:12 am
Posts: 294
Location: Victoria, B.C.

On to the mast box. In the 1st photo of the dry fit you can see I modified the cabin top support pieces. I just made them deeper than required, notched the ends and center to fit the pre-made slots and placed the holes. I did this with the idea of adding places to hang lanterns, lines, coats and what have you. The 2 aft holes in the forward section are blocked with the mast box so I am going to add pegs to these. The only downside I could see is the possibility of banging my head because they intrude further into the cabin space so I may be cursing the idea later.


Attachments:
File comment: The dry fit, again note the hanger holes in the cross pieces
P1020546.jpg
P1020546.jpg [ 53.25 KiB | Viewed 299 times ]
File comment: I also added a couple of cleats on either side of the stem to support the bottom of the mast box. Likely not needed but seemed like a potential weak spot
P1020549.jpg
P1020549.jpg [ 37.26 KiB | Viewed 299 times ]
File comment: Glued bottom puzzle piece of box first, lining up by fitting into sole sheet on other side. Masked off puzzle joint 1st to make sure they were not epoxied together. Then glued in port side of box
P1020550.jpg
P1020550.jpg [ 47.67 KiB | Viewed 299 times ]

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Mon Jul 09, 2012 10:26 am

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Joined: Sat Jan 07, 2012 11:12 am
Posts: 294
Location: Victoria, B.C.

More mast box


Attachments:
File comment: Tried to figure out how to get good fillets inside the mast box. Glued forward section of box in place next, all were pre-taped. Before I placed the starboard side of the box, I did the fillets on the port side
P1020552.jpg
P1020552.jpg [ 57.22 KiB | Viewed 299 times ]
File comment: Tape removed to give 2 good fillets. Then ran a thickened bead of fillet material along edges for starboard side and placed that section as well. Smoothed fillets into corners on starboard side and removed tape, all through top of box and slot in bulkhead 3. Not the best but reasonable.
P1020553.jpg
P1020553.jpg [ 51.76 KiB | Viewed 299 times ]
File comment: Clamped overnight and then applied tape for fillets on outside of box. The inboard doubler for the hatches in bulkhead 3 come right up to the mast box so there is a very solid joint at this point.
P1020554.jpg
P1020554.jpg [ 39.36 KiB | Viewed 299 times ]

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Mon Jul 09, 2012 10:34 am

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Joined: Sat Jan 07, 2012 11:12 am
Posts: 294
Location: Victoria, B.C.

Final mast box.
QUESTION - it says to fiberglass the top of the box where it will protrude through the cabin top. Do I carry the tape over the top edge of the box as well?


Attachments:
File comment: Rounded off the forward corners with 1/4 inch roundoff bit prior to applying tape
P1020556.jpg
P1020556.jpg [ 38.03 KiB | Viewed 297 times ]
File comment: Fiberglass tape to forward edges. Wet epoxy to box first, placed 2 inch tape onto wet surface then applied a second coat to saturate it.
P1020557.jpg
P1020557.jpg [ 53.24 KiB | Viewed 297 times ]
File comment: Fillets done, masking tape removed and forward corners fiberglassed
P1020559.jpg
P1020559.jpg [ 44.67 KiB | Viewed 297 times ]

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