Sunday, August 28, 2016

Drilling & Filling

Finished up drilling & chipping out the final two holes in the bottom of the keel. Once this was done I waxed up the bolts that'll be used to secure the skeg and taped them 'Up' through the holes I drilled earlier. This will make it easier to line everything up later.
Mold release wax on the bolt shanks
Taped in place from the bottom up!
Next mixed up a runny batch of epoxy & chopped strands. These small strands of fiberglass are only 1/4" long or so. Just poured them into the holes. Quick & easy. These will set to be rock hard and able to take all the torque I can put on them when the skeg is insalled.
Back filled with epoxy & chopped strand fiberglass
Just dry fit a piece of the 'Duragrid' I bought to go on the bottom of the box keel. The flexible water tank will sit on this. Hopefully there'll be enough air circulation to prevent any mould from growing down there.
Duragrid dry fit
Going back out to the shed this afternoon to start the drip tray that'll go under the engine.


Friday, August 26, 2016

More Box Keel

So looking at the stuff I gotta stuff in the keel, skeg bolts & backing plate and the prop shaft tube, I gotta do the skeg stuff first. If I put the prop shaft tube in I won't be able to get to the bottom of the box keel at the stern.

Out comes the ole' trusty laser level! Let's get this puppy lined up!
Lining up the skeg backing plate
I only had 1 reference hole from the first test fitting. I need at least two to get the backing plate lined up properly. The vertical line from the laser makes an easy job of this.
Backing plate in place
I drilled all the holes and dropped the bolts in to see how they'd line up. Just a waste of time really. Next step is to overdrill the holes so they can be filled with reinforced epoxy. This gives a better core for bolting the skeg to the keel.
Drilling more holes in my nice hull! *sigh*
The trick here is to not cut all the way though. You want to leave the outer fiberglass in place. The old hole saw I had has a 1/2" piece of plywood stuck in it so there's no chance of going all the way through the bottom of the keel. Most of the 'digging out' of the remainder of the core is with a chisel & air sander.

Couple of finished holes.
ACME Holes!
 My neighbor, Robert, gave me a 24Volt cordless drill about 10 yrs ago. It's been a real workhorse. Along with the drill he gave me 3 extra batteries to go with it. One has bitten the dust completely.
Pooched 24V battery.
Another one has been intermittent. A real PITA when you need it to work. So in order to see what's going on I pulled it apart. One of the contacts wasn't soldered on and just a weak crimp holding it in place. I suspect that was the culprit so I soldered it fast!
It's on the charger now so we'll see how it goes tomorrow.

35C in the shed when I left 10 mins ago. Fans going full blast and it's still a scorcher.

More tomorrow.


Thursday, August 25, 2016

Before the rains came

Wanted to finish up some of the work on the stern bearing carrier before the rains came. Dragged my mockup shaft out of the boat and fitted the parts together to see if I damaged the bearing carrier or cutlass.

First task was to drill dimples into the cutlass for the set screws to lock into. This will prevent the cutlass from spinning in the carrier should the shaft get seized to the bearing.
Dimples cut into cutlass
Used a little electrical tape to protect the threads and prevent me from drilling too far into the cutlass.
Tape added to drill bit to protect threads.
Worked like a charm. Set screws were put back in with some thread locker.

Next up was drilling and tapping for the Spurs line cutter attachments. Little bit tricky as the brass is really soft and if you're not careful the drill bit will wander. As per instructions I drilled right through the cutlass.
First hole drilled & tapped for Spurs attachment
After a bit of tweaking it all came together.
Spurs line cutters & bearing carrier attachment in place.

I did a little spin test of the bearing carrier & cutlass on the mockup shaft just to show it's not damaged. It is smooth as silk!

That's about it for today. More tomorrow.


Wednesday, August 24, 2016

There are times

For the for the first (and only) time boat builder good and proper tools are not usually a priority. If they last the life of the project that's all I can hope for. Sometimes there are needs for specialty tools. Welders, presses, cutters etc. The expense of buying these cannot be justified if they'll only be used once or twice.

So today's task was to press the cutlass bearing into the bearing housing.
Bearing carrier with cutlass partially pressed in
So for this job I decided, upon advice from the Interwebs, to make my own tool for this job. A piece of threaded rod, some nuts and a few large fender washers would do the job (maybe).

I needed to tack the fender washers together due to the large hole in the large one. No biggie, I have a little inverter stick welder. Perfect tool for that job!
These would bear against the bearing carrier and the cutlass. As I turn down on the nut it would force the cutlass into the carrier (in theory).
Using the custom tool to install cutlass bearing
So to make a very long (3-1/2 hrs of frustration) short I ended up only getting the cutlass about half way in. The fender washers collapsed under the stress and split in half making my tool useless.
In the end, after about 3-1/2 hours of frustration I called it quits. See the video below.

Packed up my shit and headed to see my buddy Vince. He's got a repair shop in Prescott and has a hydraulic press! The perfect tool for the job!
The proper tool for the job
Thanks to Vince and Andy for getting me past this step. It's a small step but an important one.


Wednesday, August 17, 2016

No Methodology

I really have no methodology on building this boat. I usually have no or very little idea what I'm going to do that day until I get in the boat.  I suppose that comes from never having done anything like this before.

This morning I decided to tackle one of the little jobs that I've been putting off for awhile. It's going to be at least a week or so before the lil' Yammy comes home so I tackled the sanding in the engine bay.
Engine bay getting sanded and maybe a little fairing before bilge paint
It's been a minute or two since I've done any sanding like this. Kinda forgot what it's like! There's something sadistically satisfying in making all that dust!
Sand On Dusty Fella's!  ;-)
So back to methodology. I suppose you can work from fore to aft. Port to starboard or vice versa. Depends on how disciplined you are. I'm all over the map. One day it's bulkheads I'm fixated on. The next it's the gluing and taping of stringers and today it was sanding. I dunno, maybe that's part of the fun of doing it yourself.

It's a lil' warm out there now so I'm calling it quits for the day. Tomorrow I'll finish glassing the stringers! Hey, I have a plan! ;-)