Beginning Rudder Head Assembly

Posted by Zachary Wiest in Epoxy, Modifications

Because my rudder is quite complex with all the electrical wiring, a lot of thought has gone into the assembly.  I glued one half to the the spacers with silica thickened epoxy and clamped it down.  This is just the beginning.  I have some routing for cabling to do before the rudder head meets the other half.  I must also primer and paint the actual rudder assembly first too.

Time Spent: 0.5 Hours

Total Time In Build: 126.5 Hours

Installing Mast Step and Speaker Boxes

Posted by Zachary Wiest in Epoxy, Modifications

I just installed the mast step using some of the same techniques I used for the daggerboard trunk: Marking the drilling pilot holes from the inside, drilling countersunk holes from the outside, gluing in place with silica thickened epoxy, then running 6 wood screws.  The speaker boxes are only attached with thickened epoxy.

Time Spent: 1.0 Hours

Total Time In Build: 126.0 Hours

Epoxy Coatings

Posted by Zachary Wiest in Epoxy

I spent a little time epoxy coating the speaker boxes, rudder, and daggerboard.  The coating on the speaker boxes was quick and simple.  I don’t need them to look good as they will be hidden under the forward seat.  The daggerboard and rudder received nice smooth coats as the primer will be next to hit these surfaces.

Time Spent: 1.0 Hours

Total Time In Build: 125.0 Hours

Building and Shaping the Mast Step

Posted by Zachary Wiest in Epoxy, Tools

At the base of the mast a wooden “step” is built to help support it and keep it in place.  I assembled the step with silica thickened epoxy and counter sunk wood screws.  It needed a little shaping to make it fit into the hull.  That was done with the random orbit sander.  The screw heads will be covered with wood flour thickened epoxy.

Time Spent: 1.0 Hours

Total Time In Build: 124.0 Hours

Installing the Daggerboard Trunk

Posted by Zachary Wiest in Epoxy

I have long had the daggerboard trunk complete, but today it was time to install it.  I spent a good amount of time making sure it was on centerline and plumb before drilling any holes.  The trunk is epoxied to the bottom panel and to the center frame.  Countersunk screws running through those pieces ensure it is strong.  I covered up the screw heads with wood flour thickened epoxy which I will sand smooth later.

Time Spent: 1.5 Hours

Total Time In Build: 123.0 Hours

Misc Epoxy Work

Posted by Zachary Wiest in Epoxy

Today I mixed up some epoxy and thickened it with silica to do some miscellaneous gluing and hole filling.  I glued in the center seat supports that I built, glued together the mast partner, and filled in to holes for the rudder pivot bolt.  These holes will get drilled later at a smaller diameter.  This ensures it is watertight where the bolt will run through.  Gluing the seat supports was quite difficult because I had to ensure they were perfectly vertical and square to the center frame.  No pictures today as I didn’t feel there was anything worthwhile to show.

Time Spent: 2.0 Hours

Total Time In Build: 121.5 Hours

Seat Supports / Instrument Panel

Posted by Zachary Wiest in Modifications, Sanding, Tools, Woodworking

Today I used some 3/8″ Okoume ply to make some center seat supports and the removable instrument panel.  It took quite a bit of time to measure, cut and form.  I used my jigsaw, hand saw, block plane, and random orbit sander.  The panel will contain the on off/switch, battery meter, cigarette lighter / power port, iPod/USB hookup, and the battery charger.  This panel will be removable to reduce weight when not needed.  The seat supports and the panel also form a battery box.

Time Spent: 2.0 Hours

Total Time In Build: 119.5 Hours

Speaker Boxes

Posted by Zachary Wiest in Modifications, Woodworking

I swear I haven’t been lazy! I have been busy and on vacation.  I got back to work by building some speaker boxes for the forward frame.  Because I cannot ensure that the speakers will be watertight, I wanted to put a box behind them in the forward frame.  This will allow me to assure that the forward buoyancy tank is impervious to water.

Time Spent: 1.5 Hours

Total Time In Build: 117.5 Hours

Making a Larger Center Seat

Posted by Zachary Wiest in Decisions, Modifications, Tools, Woodworking

Because I have chosen to add an electrical system to the Skerry, I needed to make a place for the battery.  I chose to install it under the center seat, right behind the center frame.  The battery stuck out a little bit, so I elected to make a new seat the extended 3 more inches to stern.  I traced the original seat, adding the portion I needed, then cut it with my jig saw.  I will use the original seat to cut a panel that fits vertically under the new seat.  This removable panel will house the electronics and hide the battery.

Time Spent: 1.0 Hours

Total Time In Build: 116.0 Hours

Sanding The Interior, Again – Part 1

Posted by Zachary Wiest in Sanding, Tools

So another long journey of sanding begins.  I must sand the entire interior to smooth the epoxy covered fiberglass.  It is about a 50/50 fix between power sanding and hand sanding.  Reaching over the Skerry’s sheer makes this a difficult task.  Also, when hand sanding, I constantly need to vacuum up the dust as it builds up quick.  Fortunately the random orbit sander has a vacuum attachment.

I only spent a couple hours sanding today.  It was hot and a lot of work.  I sanded the majority of the bottom and #1 panels.  I don’t plan to sand in the bow and stern compartments as they will be sealed up by the seats.  You will notice in the pictures that sanding makes the beautiful epoxied wood look gray and ugly.  It is supposed to look like this.  Once another layer of epoxy or varnish hits it, it will look good again.  I just have to smooth everything out before those final pretty coats.

Time Spent: 2.0 Hours

Total Time In Build: 115.0 Hours