Boat in a box - the Shu3

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Shu
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Re: Boat in a box - the Shu3

Post by Shu » Mon Sep 29, 2014 4:49 pm

Thanks Brad. It looked like a great regatta; I'm really sorry I missed it. I hope to be back out in a few months, maybe less. Here's the PG rated photo of the knee, as of yesterday. Fortunately, there is no R-rated version from when the world's largest band-aid was removed after 2 weeks. I never saw the x-rated version, since I never peaked under the band-aid. For the curious, this was a partial replacement, patello-femural to be precise.

I promise not to pullute this thread with any more ugly knee photos.

edit: Ugly knee photo deleted. I think we all had seen enough of that.
-Steve
Steve Shumaker
USA 1183

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Shu
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Re: Boat in a box - the Shu3

Post by Shu » Wed Oct 08, 2014 6:54 pm

I'm paneling the bow area now, and the plywood isn't wanting to conform to the shape I want. It's fine longitudinally, but transversely, the curvature just changes to rapidly. I've decided to add some short stringers for the first foot to have more control over the transverse curvature.

Also, this area will be quite deep and narrow when the boat is turned over, so I'm sealing everything with 3 coats of epoxy now before I put the panels on. I will post photos soon.
Steve Shumaker
USA 1183

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Shu
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Re: Boat in a box - the Shu3

Post by Shu » Mon Oct 13, 2014 6:28 pm

It's time to post some better-looking pictures.
Here is the bow area with two short stringers added, and the interior surfaces all epoxy sealed. The photos also show the starboard panels being glued just short of the stem, and some views of the bow with the screws and battens removed.
Attachments
IMG_3410.JPG
Notice the extra stringers in the forward 1 ft. Note also the sealed surfaces in this area that will be hard to reach when the boat is turned over.
IMG_3414.JPG
The clamps help twist the battens
IMG_3416.JPG
IMG_3422.JPG
There is enough deadrise in the bow area to bevel each side prior to gluing on the opposite side. Note there is some puckering at the screw holes; this will sand out easily. It also will be covered by carbon tape (edit: it will be covered by another layer, and then carbon tape; duh).
IMG_3419.JPG
How it looks with the screws and battens removed. To avoid the brace, I stopped just short of the stem on this side.
IMG_3420.JPG
Another view
IMG_3427.JPG
Still another view
Steve Shumaker
USA 1183

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Shu
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Re: Boat in a box - the Shu3

Post by Shu » Wed Oct 22, 2014 9:48 pm

Here are photos of the finished first layer, which was completed yesterday morning.
Attachments
IMG_3433.JPG
IMG_3435.JPG
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rand
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Re: Boat in a box - the Shu3

Post by rand » Thu Oct 23, 2014 4:28 pm

Looking like a boat!
Rand Arnold
International 14 USA 1143
"A Bumblebee Called Kate"
(former US President, former US Measurer)

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Shu
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Re: Boat in a box - the Shu3

Post by Shu » Fri Nov 21, 2014 6:01 pm

The second layer of 2mm ply is half-way finished now. Progress is tedious. I'm filling the joints with thickened epoxy as I go to take advantage of chemical bonding.
Attachments
IMG_3437.JPG
About 1/3 of the way done with the 2nd layer
IMG_3438.JPG
1/2 way done with the 2nd layer
IMG_3440.JPG
IMG_3441.JPG
Steve Shumaker
USA 1183

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Shu
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Re: Boat in a box - the Shu3

Post by Shu » Thu Dec 11, 2014 10:57 pm

Here are some more photos of progress with the cold-molded plywood bottom. These photos show more details of the process of gluing down a panel, which I will describe here:
1. Cut a panel approximately 2 to 2.5 feet long to fit.
2. With a razor blade cut the panel into 3 more or less evenly spaced pieces (that step is missing here).
3. Index the fit with small nails or screws.
4. "Paint", with liquid epoxy, the panel and it's corresponding location on the first layer, which is already on the boat. This saturates the surface, and keeps the wood from sucking up the epoxy glue and creating a "dry" joint.
5. Apply thickened epoxy glue to the boat side with a toothed spreader. The teeth ensure an even thickness of glue.
6. Align the new panel, using the index nails or screws.
7. Staple the panel down to each stringer using battens to evenly distribute the pressure. I use clamps instead of staples at the chine log.
8. Remove screws (if any) and pull up the battens with staples after the epoxy has cured about 24 hours (this gets harder to do the longer I wait).
Attachments
IMG_3450.JPG
The prefit plywood panel "painted" with liquid epoxy. Everywhere else on the boat I would have cut this down into three shorter panels to deal with the compound curvature, but at this point on the boat the stringers are all pretty straight and there is only modest twist, so the whole panel conforms nicely to the shape of the hull
IMG_3456.JPG
Applying the thickened epoxy with a toothed spreader
IMG_3457.JPG
Thickened epoxy applied and ready for the panel
IMG_3451.JPG
A closeup of the thickened epoxy glue
IMG_3461.JPG
The panel is started with index screws through the centerline batten
IMG_3467.JPG
The panel fastened down with battens. an additional batten is clamped down just above the chine, since this tends to be a problem area, and I can reach it with longer-jawed clamps.
Steve Shumaker
USA 1183

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Shu
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Re: Boat in a box - the Shu3

Post by Shu » Mon Dec 15, 2014 7:44 pm

Here's the panel with the battens removed.
Attachments
IMG_3470.JPG
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EdS
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Re: Boat in a box - the Shu3

Post by EdS » Wed Feb 04, 2015 10:24 pm

Shu,

any updates on the build?
Roaring Forties GBR1524

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Shu
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Re: Boat in a box - the Shu3

Post by Shu » Thu Feb 05, 2015 12:33 am

Hi Ed.
I finished skinning the bottom this past weekend. I should take and post a few photos. Next will be cleaning up the chine joint for the topsides and scarfing the 4mm topside sheets together. I should take and post a few photos.
Steve Shumaker
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Shu
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Re: Boat in a box - the Shu3

Post by Shu » Fri Feb 20, 2015 7:55 pm

Finally some new photos. The bottom is done. The epoxy stripes give a good approximation of a lines drawing. The starboard side is ready for the topside panels, which I started cutting out this morning.
Attachments
IMG_3527.JPG
IMG_3521.JPG
IMG_3512.JPG
IMG_3528.JPG
Steve Shumaker
USA 1183

Hendo
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Re: Boat in a box - the Shu3

Post by Hendo » Fri Feb 27, 2015 7:17 am

looks great steve! Keep her light and you might have somthing.

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Shu
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Re: Boat in a box - the Shu3

Post by Shu » Mon Apr 06, 2015 8:58 pm

The starboard topside panel is ready to be glued in place. Since this is only 3 ply 4mm plywood, the outside grain runs vertically, reducing the span to 6-inches or less. This means I have to scarf 4 panels together. This time I've refined the technique a bit more:
1. putting masking tape on the backside of the joint edges to support the feather edges that are parallel to the grain.
2. starting with the electric plane, then the orbital sander, and finishing by hand sanding with a wood block to get a flatter, more uniform scarf.
Attachments
IMG_3682.JPG
The panel dry-fit in place. There's quite a bit of flare at the bow, so a number of screws are necessary to get the plywood to conform to the flare.
IMG_3701.JPG
Sealing the hard to reach bit in the bow area before I glue it down.
Steve Shumaker
USA 1183

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Shu
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Re: Boat in a box - the Shu3

Post by Shu » Fri Apr 17, 2015 12:49 am

After a marathon gluing and fastening session, the starboard topside is on. There are about 47 linear feet of glue joint to attach one panel. Given that each side of the joint gets painted with liquid epoxy prior to applying the thickened epoxy glue to one side, that's a lot of gluing. And then temporary fasteners at 4" to 6" spacing. Whew.
I'll try to take some pictures to feed TG's clamp addiction. :wink:
Steve Shumaker
USA 1183

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Shu
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Re: Boat in a box - the Shu3

Post by Shu » Fri Apr 17, 2015 5:58 pm

Here are some photos. Lots of clamps were used to keep -TG amused. As usual, I've used battens to distribute the clamping or fastening pressure.
Attachments
IMG_3703.JPG
Keeping the clamp industry booming.
IMG_3704.JPG
With fasteners, battens, and clamps removed.
IMG_3705.JPG
The chine has been planed flush. The extended bit of the gunwale at midships will help with vacuum bagging the carbon reinforcement at the shrouds.
IMG_3708.JPG
Steve Shumaker
USA 1183

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