Read my face: three years in the garage and now…
PS! Arno, Ranno and Veiko – thanks for helping me with the mast trial 🙂
Read my face: three years in the garage and now…
PS! Arno, Ranno and Veiko – thanks for helping me with the mast trial 🙂
Over a long period of time finally we had a nice weather today, so I headed out with 2 friends & Itatae to measure fixing block locations for beams.
She looks cute ain’t she 🙂
A pretty grand moment 🙂
Its already August – soon enough nasty long, damp & dark winter will knock on the door… Still I have some glimpse of hope, as I finished port hull paint job — I only need to fit windows, main hatch hinges and rudders.
Port hull with fresh paintjob
Just look at these neat curves 🙂
Just some few odd jobs left… here’s centre beam under pressure waiting epoxy to reach its final stage (slow hardener for gluing; 50% fast, 50% slow for fillets)
Starboard hull with its new paint (same as port hull — Tikkurila Temadur 20)
Playing with the paint & sniffing the fumes….
… two part epoxy based Tikkurila Temacoat RM40 serves as primer for the hull, I will let it to set for a few days, then there will be applied two part polyurethane Tikkurila Temadur 20 fas a topcoat. Interiors are already coated with several layers of Temacoat, which is a bit easier to apply in constrict spaces, as it do not go off too quickly after mixing and its a bit more viscose as well, a true virtue considering the situation where painter has to squeeze himself into the rear section of cabin, size of a smaller nightstand, armed with pot of potent smelling paint, flashlight, small brush and watering eyes.
… a fancy DIY knob for main hatch locking system, made of 2 layers 6mm plywood (will see how it works…)
… and little bit of woodwork as well — a base for jib block, made from 2 pieces of oak, clued and screwed onto the hull.
I decided to abandon jib traveler and went for barber haulers.
Now I need one dry and warm day for painting the topsides and another for hull sides…
Port hull almost done, still lots to do…
… waiting in the list:
Those freshly glued front deck stringers got nice and cozy overnight stay under this i-love-to-hassle-with-masking-tape tent
Bunks are ready for port hull. Now there will be some paint job (Tikkurila Temacoat RM40) and stringer job before gluing the decks on. Looking good, hopefully I could keep up the pace…
Epoxy cooking in winter conditions… coating bunk undersides.
There has been pretty few progress since port hull went 3D, but thanks to yesterday’s long hours in garage all the bunks and stringers are ready for next phase, which means a little bit of sanding and then painting underneath of bunks and watertight compartments as well, before gluing bunks in.
So… second hull got stitched up and yesterday I made some nice fillets for keel & bulkheads for 2 sections… I think its time to talk about little variations and changes I have made and plan to make into workflow, just to make whole process a little bit smoother and less time consuming.
Those modifications seem rather irrelevant, but again, when most of the (epoxy related) works are carried on by single person, then every little nuance start to play important role, especially those that help to reach results easier and faster.
Port hull, all stitched up, with glued sheer stringers and additional bunk bearers.
A key for levelling the hull.
shot by mr Gab
A friend lent me a helping hand, so applying the roll & tip technique was a piece of cake. It took only 1,5h hours to entirely coat the hullsides. After few hours we added second coat and in next morning Itatae received third one. Im thinking to add fourth layer as well and this time I plan to add some thinner as well, to get a bit smoother surface.
By the way – I switched from Tikkurila Temadur 20 (polyurethane) to Tikkurila Temacoat RM40 (epoxy based), which is much easier to apply as it does not give such potent fumes as the first one, also it has a bit longer pot life as well – which are much appreciated characteristics when you are amateur builder working in tight conditions. So, will see how this thing will work out in the end.
Starboard hull waiting for some sanding and then paint job and off you go… (… I need to figure out how to configure jib sheet block attachment and main hatch locking system, though…)
it has been long time since I last wrote to you… but, still, there have been some advancement in the Garage. What I managed to achieve is — despite of too cold spring (bad for epoxy cooking) and too hot early summer (hard to stay put in shady garage) — gluing coaming for main hatchway and constructing main hatch, glassing topsides of the hull (decks and cabin). Later process has been pretty emotional :p — getting glass over the upper deck stringers without air bubbles and sticking it onto underside of the sheerstringer was business that one may call PITA. Nevertheless, work itself is the best teacher and when I finally got into glassing the forward deck I managed to execute the process with minimal losses i.e. decently smooth finish, which requires minimal sanding later on.
So lets have a quick glance of the mess I have created (hull is turned so we could have a clear view of the sight).
1. exhibit A
– after fiberglass on deck and sides of the sheerstringer was wetted, next move was to try tap it into place underside of the sheerstringer using a brush. With not much of luck. Things got under control when I brushed undersides over with epoxy and WS Microlight filler.
Note that I have already covered up some of the traces (using good old elbow grease and 60 grit sandpaper).
2. exhibit B
– so here you can see me trying to get glassfiber down from cabin sides stick to underside of the sheerstringer, but this time, I didn’t cut the glass flush with the corner – instead I let the epoxy set for a while, then after it got really sticky, I removed the excess and applied fillet (Microlight) right a way on top of it.
Again, this evidence have had some touch ups already.
3. exhibit C
Well now I can be proud of myself and honor my humble figure with Distinguished Service Order as I demonstrated unprecedented capability to evolve and learn from past mistakes whereas this time (forward deck) I produced nice and neat fillets (Microlight) and let them set semi-hard before I moved to sheerstringers undersides with glassing. I removed the excess of the fiberglass just before applying saturation coat (mixed again with Microlight to avoid sagging).
PS! Decks and cabin sides saturation coat were thickened with Microlight, which is rather easy to work with (whether applying or sanding it).
So now the itinerary offers me adventure down under – fillets around the keel, aft deck sheerstringer undersides, stem & stern, sanding, fiberglass tape, sanding, glass for one side, sanding, glass for other side, sanding again…
So before stinging cold from Russia struck… I managed to glue fore deck as well. Aft deck was done already in November.
Now both of them are glued, trimmed back and rounded, ready for next phase.
During nighttime it drops down to -20 Celsius outside and it takes too much effort to heat garage sufficiently for epoxy work, so I spend some therapeutic hours shaping and smoothing rudder blades. Hopefully there will be soon some nice warm lows dispatched from North Atlantic so I could resume to gluing work, which means attaching the cabin sides and top, small round fillets for deck stringers, fillets for holes left by temporary screws I used occasionally during deck works.
Broadsides & bulkheads of the port hull were cut out already in summer. So for a change of scenery I started with gluing deck-beams and bunk bearers, also I prepared nice thickened-epoxy holes for taking inspection hatch bolts. Maybe its overkill… on starboard bulkheads I used just screws.
… then continued with beam web pairs, which also ended previous sanative session with a cruel fact that I miss few inches of ply sheet in order to complete all three pairs. Apparently when I produced rudders, stem & stern posts in spring, I went for too excessive safety margins…
Spend some fumy hours in garage and painted 2 stern & 3 stem sections. When deck is fitted it would take Houdini to paint those afterwards.
My choice of weapons is based on local knowledge (advice from recognized boat builder & ice sailing enthusiast Vaiko Vooremaa). So I went for white Tikkurila Temadur 20, which is semi-matt two-component polyurethane paint. This smelly magic has a MED (Marine Equipment Directiv) approval, which means if decrypted that from now on I could store in those compartments pretty hostile substances – from chicken manure to nuclear waste if I may happen to cruise around Fukushima. I have brushed this vigorous stuff 3-4 thin subsequent layers… so I could pull this Fukushima plan off indeed.
The result isn’t worth of presenting in Louvre, but compartments future lodgers, like coils of rope, spare sails and corned beef hardly ever have possessed spectacular taste for fine art.
PS! After spending few sweaty afternoons in workshop with polyurethane paint I started to understand the compassionate look of the color shop dealer when I told him that: no I do not have a paint-gun, nor do any of my friend does not have this fine gadget, and yes, Im gonna use just a brush and solid determination of honey badger with hypomanic disorder.
Some tweets about stuff I have used.
First, spreading the epoxy… for a large surfaces, like broadsides I found pretty convenient to use wallpaper spreading rolls. You have to clean them thoroughly afterwards, though.
Yes comrades, I sure did experiment with various rollers available in housing stores and none of them satisfied me enough (maybe those fancy West System roller set 800 & 801 would give a more fancier outcome). I found myself experimenting with plastic spreaders likewise, but not so much of success, as resin tend to turn kind of foamy…
Bulkheads, bunks, stiffeners etc has been coated with using brushes. With a certain amount of trial & error I finally kinda get the knack: first I pour out a resin trail, then brush it longitudinally with rather strong strokes (with divaricate bristles) subsequently I will spread the resin crosswise and diagonally from initial track, using smooth and not so vicious strokes. I still have not acquired the skill of producing a perfect smooth surface, there will be still some waviness left, but the outcome has been significantly improved since I implemented this technique.
Radius fillets for bulkheads, keel and bunks…. PITA for me in first place as I tried to use radius tools cut out from plywood. Those are too inflexible, so suitable only for amateur builders blessed with Houdini genes.
Also I found myself experimenting with radius tools cut out from the canisters of car window washing liquid – too flexible… Finally I stumbled upon nice bright yellow plastic spreaders in construction store that I shaped onto desired radiuses. They work like a charm. Now I would sculpt those fillets until end of my days… Well kidding, two hull worth of radiuses will do fine 🙂
For mixing epoxy I found nice ice cream cups (black ones in the pic) which are very flexible and ductile, so most of the times I have succeeded in braking off cured epoxy after the work has done. Most of the times I would pour mixed epoxy into plastic can which is usually used by decent house wives for storing the raw cranberry jam in the deep freezer. This can has a bit more surface than a ice cream cup, so epoxy does not go off so quickly. It makes great utensil for mixing the fillers as well. Also reusable most of the times.
Gluing stuff… In one of my previous post I already explained why I deviated away from using copper nails as a temporary fasteners. So I went and bought a bunch of stainless steel screws. Stainless because I presumed that I may not retrieve all the screws after epoxy has cured. And the practice demonstrated that my assumption was not so wrong after all. Few of those scrawny screws (right on the photo) decided to stay in. Despite the fact that I had cleared the heads from clue with acetone rag, still some clue managed to spoil those tiny lobes. Lesson learned… so I abandoned those and started to use screws with bigger heads (in the middle of the photo). Those are 3mm diameter & 12 mm long and do the job.
Last but not least – when messing around with epoxy or with random orbit sander don’t forget to wear a proper mask. I have 3M half-mask with detachable organic compound and dust filters, which I could combine depending the situation. 3M has a selection of masks in various sizes, so you can choose best fit for you. Im pretty pleased with one I got.
Im not sure if its overkill, but I manufactured some nice minuscule fillets for covering the stitch holes of diagonal stiffeners. Fancy stuff, my friends.
Gluing bunks. Deviated from the building instructions a bit – I did not stitch the bunks, instead I went for temporary screws and some nice bricks. Also I did not loft the curvatures like Wharram suggest, therefore I took the measures in situ and cut out the bunks accordingly with strait edges against the broadsides. The camber of the broadsides leaves just a few millimeter wide gap between bunk and side, which would be easy enough to fill with thickened epoxy.
Fillets. After colloidal silica and epoxy mix has been cured next step was sculpting some nice radiuses (low density filler) for upper- and underside of the bunks. Later one made me wish I was born as a bat – a job not suitable for sweating out the hangover 😉
I waited until upper side radius was almost cured, then laid gently 100mm 175g glass tape, smoothing with light strokes of brush until it was leaning tight against surface after which epoxy was brushed over.
PS! Peanut butter. If its not necessary to squeeze fillet into some narrow gap then peanut butter consistency would work best. It paid off to spend an extra minute to measure out the right consistency. At least for me.
I must admit that I did not overwhelmingly enjoyed this head down to the knees epoxy cooking… but nevertheless it is great pleasure to see how step by step those wobbling plywood panels shape up into a sturdy and beautiful boat… all done by my own two little pale hands 😉
And my condolences to this poor quay whose path may cross with this hefty stem fillet…
And again I can not get enough of those dare lines of Tiki’s – now all filleted and reinforced…
Today I continued with fillets. This time were the keel fillets in to-do list, those will be glassed as well.
I use West System 407 Low Density filler. For applying correct radius I produced plywood spatulas. But they are inflexible, so I guess I shall replace them with metal spreaders shaped in desired form…
Now as I have removed stitches of the diagonal stiffeners, I would like to share some notes on that. Cause God or Devil is in the details…
This was first time for me to perform such kind of gluing method and again I had to learn it by hard way how to make things easier.
So what I would like to point out first is that if you would like to glue all the stiffeners with single evening its better to have helper. One is stirring and spreading the glue and the other is stitching. Yes, one could install the wires to the hull prior glue spreading – but its pretty nuisance to spread the glue between those prickling wires, which will tear up one’s nitrine cloves pretty soon… Actually, when deploying the stiffeners it does no harm to wear leather cloves on top nitrine ones against the prickling ends of the wire.
What I also learned is, that when tightening the wire, its worth to pull it slightly away from the stiffener in same time – in this manner there seem more force transferring into tightening rather than braking the wire.
What you may also like to take special care of is drilling the holes – its better to have them right on the edge of stiffener, when they are inside from the line, its hard to remove the wire after the glue has cured. When the holes are too far away from the stiffeners edge then there could be a bit trouble in tightening.
Wharram suggest to drill small holes for stiffeners stitches (previously stitching the hull there was suggestion to have holes approx. twice the size of the wire) – and I can see that then you have much less epoxy surrounding the wire in the hole which makes wriggling the wire out much easier.
Wriggling – get a notch on that. It concerns the removal of the wires. I seldom used pliers to pull out the wires.
As with most of the other thousand things in life, its rarely the laboured force that helps to achieve your goals.
So take your time, snap the wire outside, bend it back straight, unwind other side and then start to slightly wriggle and turn the wire and when you feel grip of the epoxy starting to loosen then its time to pull wire smoothly out. And yes of-course, during the gluing process its smart to remove as much of excess epoxy as possible, no doubt on that.
Few weeks ago I bought from Mass last pieces of Douglas-Fir needed to complete hulls. It means two 5,45m 105x52mm logs.
Im still missing pieces for the crossbeams: they need to be 3,81m long with cross section of 120x20mm. I have to hope a miracle on that!
Anyway, I had to use again lots of Veiko’s elbow grease to cut them in suitable battens and planks.
Thanks again Veiko and Jaanika! Your help is again appreciated a lot!