Weeks 6 & 7 Finishing the outer hull skin

Over the last two weeks we have been finishing the surface of the outer hull in between doing exams for our qualification. This time aslo saw the moving on of Dan and help arriving in the form of Paul H and Nick L.

Week 6 saw us sheath the outer hull with cloth and epoxy resin and an outer layer of peel ply on the Monday. On Tuesday after ripping off the peel ply we saw the brighter hull skin show up all the filling and fairing that had to be done over the next week or so. One area at around station two on the port side showed up a significant bulge in the foam so it was decided that the best thing to do would be to cut out that section of the panel below the waterline to the keel and fit a new panel in. After cutting out the area and cleaning off the bearding line on the hog we found the offending spot causing the problem, a very slight lump on the hog which was just enough to through the foam away off it's line. A strong lesson was learned and we were very grateful the rest of the bearding line was so well faired off. The new panel was fitted in after working flat out all day Tuesday on it and by the evening we had it clothed, epoxyed and peel plyed.
On Wedneday we came in a ripped off the peel ply and the new section faired superbly. From then on it was a case of filling the outer hull with epoxy and lightweight glass bubble filler and sanding off to make it fair. The first layer was a light coat to see how the whole thing lay and to get into a swing of the process. On Thursday the hull looked like it had been basically iced as the filler was plastered on so thickly. We took the friday off to head down to Wadebridge in Cornwall to deliver the lead ballast keel mould to the foundary where we had a tour of the process.

This last week saw us sand in the mornings off a coat of cured filler apllied the previous day and re-apply another coat of filler and over the week a really nice fair hull slowly appeared. Each day saw less sanding and filling which freed up time for us the start making other components like the centreboard case and centreboard along with scarfing together spruce for the mast which I have decided will be the 22'8" Marconi or Bermudan Rig.

I finished this evening completely shattered after two hectic weeks of physically challenging work, alongside exams and coping with varoius glitches along the way. The fact that we only have one completely over stretched tutor (whom I saw very fleetingly at times) supervising 9 boats for the last 8 days only made matters more frustrating. Hopefully the much missed Bob will make a full recovery and join us again soon.
Next week is the beginning of phase 2 when we turn the hull over on a new cradle and begin the innner skin and fit out.

Week 6 Oar & Spar Week

This week was given over to making oars for those building rowing boats and paddles for those building canoes and larger sailing vessels. I made a paddle for getting the haven back into shore should the wind fade but if the budjet stretches I will probably add a small 2.5hp otboard. I was a bit dissapointed I could not make an oar as the example looked fantastic so I encorporated some on the oars features into my paddle by scooping out the face of the cheeks on one side with the bollow plane (made earlier in the course) making a pronounced spine running down the centre planked by sappelle inlays. The other side was finished like a conventional paddle with tappered flat cheeks. This new design was christened 'the oardle'. Wednesday saw the oardle finished by fashioning the handle in with the loom again laminating in some sappelle.

I had the choice of then starting to make a boom or mast for the haven during the remainder of the week or carrying on getting things ready for glassing the outer hull next Monday. I chose to work on the hull by getting the outer stem planed and faired in and sanding off the first skim of filler. A full day was spent cleaning off the transom. This was a difficult process as the mahogany kept splitting as I planed it. I got it looking presentable enough for this point and then gave it a first stage sanding with the power sander using 40 grit. I will come back to it again after the hull is glassed.

Friday afternoon was spent finishing the ballast keel mould by adding the centre board slot pattern but this proved difficult as the two pieces of laminated plyboard to form the 30mm width cupped slightly. When glued and screwed to the mould it kicked off slighly at the very aft end. This will have to be sorted out on Monday with a laminate and then planing straight. Hopefully it will work out.

The mast and rigging was obviously discussed this week and I have decided to fit the 'Marconi' Rig to my haven instead of the Gaff. Altough still made with Spruce I think it will be better suited to my modern build and for me it will be more simple to rig and maintain.

Week 5 - The Hull is Foamed

This week saw the biggest leap forward with the hull skin fully in place. It was a relentless week of pushing forward every day but at the end of every day the progress was satisfying to see and a real buzz of interest from around the workshop with everyone saying that Foam is the Future!

We cut and fitted the largest boards to take in the waterline on Monday and then cut the remainder of our stock material on Tuesday into strips to strip plank the remainder of the hull over the rest of the week. The foam really took the shape of the hull beautifully and the finished hull has very pleasing lines. We found that Station 2 was a bit hit and miss to the fairing of the foam in one small section but was soon sorted with cable ties and a network of wires pulling and tensioning it fairly into place under the hull. Friday saw the greatest leap with the final sacraficial planks put in place and the stem laminated on and then we worked late into the evening skimming a first fill layer of glass bubbles to the all the holes left by the screws to fix on at each station.

Next week is a break at the Academy from Boat Building when we have a week of Oar and Paddle making. I will be making a paddle out of Spruce and Sapelle for the Haven to use when the wind dies and maybe there will be some time to make a boom for the mast towards the end of the week. Hopefully during the evenings I will also get some more filling and fairing done.