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Old 07 September 2005, 16:09   #61
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lots of progress

Thank you all for your words of support on this and all your helpful suggestions.

Sorry I haven't posted much for a while, its not that nothing has been happening, quite the opposite in fact.

The console construction is well under way as you can see from the photos. I am using West System 105 epoxy mixed with colloidal silica to give me a paste suitable for filleting all the joins in the plywood. It seems to be working a treat...epoxy is great stuff, it allows you to easily patch up in mistakes you've made in the measuring of the panels! I am holding the plywood panels together with zipties while the epoxy sets (known as the stitch and glue method....used to be used years ago with copper wire to make small plywood boats). The good thing aboutt he zipties is that epoxy doesn't stick to them (very well) so they can be pulled out (with a bit of force and swearing) once the epoxy has set.

A quick guide to epoxy filleting if anyone is interested:
1. drill holes for zipties in both panel to be joined
2. sand panels to open pours and "de-burr" the holes
3. make sure everything is to hand and then mix first small batch of epoxy
4. coat the areas to be joined/filleted with neat epoxy to prime the wood
5. mix colloidal silica in with the remaining epoxy to a peanut butter consistancy
6. slap on a "bead" of epoxy paste onto all joining edges
7. wack edges together and put in zipties. Ensure all edges meet and zipties are tight.
8. mix more epoxy/silica if needed (if you had any left, its probably gone off by now), and start constructing fillets by using the rounded end of a wooden mixing stick
9. thoroughly coat ones hands/hair/face/arms/legs with epoxy
10. leave to set and then pull out zipties with pliers. Fill in any holes at a later date.

Once all the panels are glued together, we will round off all the corners, then coat with G4 varnish (to provide a better adhesion of the polyester resin), lay up layers of GRP followed by tissue (to even out surface), fill and fair with resin mixed with glass bubbles (easy to sand down), then apply paint system.


Also done today was the mounting of the engine! No problems encountered here except the arm on the trim sender snapped off when we tilted it up (no idea why) so may try and fix that with epoxy!

Suggestions/comments always welcome.

Pics:
1. The shiney new aluminium fuel tank that I had made for.....the price of a bottle of Scotch - approx 70 litre capacity
Its sitting on the flange of the console to check its all ok
2. sanding/drilling all the panels ready for assembly
3. Me doing the first filleting to be done on the lower console section
4. Mike and I filleting away
5. The almost finished lower console section

Tim
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Old 07 September 2005, 16:14   #62
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More pictures:

1. pic of our first fillets...not bad if I don't say so myself! You can see how we used the zipties here
2. Fuel tank fits snuggly in the jockey seat with exceptional accuracy
3. Checking alignment for the pilot holes in the transom
4. Lower console section in the boat to make sure it fits in...no problems!
5. as above
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Old 07 September 2005, 16:18   #63
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And more...

1. Me making tea very very quickly I seem to spend more time doing this than working on the boat. My helpers drink it by the gallon
2. A simple jig used to obtain the correct position of the flange for the upper console section. This was crucial to make sure the two sections fit together ok

NOTE: this would be a good time to say (because i forgot before) that we are making the console in two sections. This makes it easier to construct and will be a doddle to coat to inside. It will then be filleted together, corners smoothed off, and glassed all over.

3. It was a good 5 seconds before Joe realised he had drilled his thumb to the plywood
4. How much stuff does it take to make a console?!!!!
5. The upper section under construction. Panel nearest is the top dash panel bit to take the gauges
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Old 07 September 2005, 16:28   #64
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last lot for tonight:

1. The garage taken over...You can see all the epoxy tubs, pumps and buckets lined up so everything is to hand when we need it in a hurry
2. Drilling the engine mounting bolt holes
3. Engine fitted and tightening the bolts....James didn't have a beer to hand, so found the next best thing...methylated spirits
4. Tightening the bolts
5. Engine on...wooohooo
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Old 07 September 2005, 17:59   #65
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mmm nice wheels! Looks like it is coming on well. Keep us informed.

M & A
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Old 07 September 2005, 18:57   #66
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Do we have maiden trip in three weeks time ? I will bring the greeny stuffy in glass bottle for the ceremony.........

Great job to yourself Tim and your helpers

Bogi
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Old 08 September 2005, 02:47   #67
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Thats looking excellent Tim, is there any room on your console for a Fixed Vhf and Plotter keep us informed so we can come and see the launch.
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Old 08 September 2005, 03:20   #68
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Looking good Tim. Might I suggest, as someone who used to stitch'n tape wooden boat seams( and fecked' up a few ), that you might want to strengthen them with tape. The joints will be much stronger. If I've missed the part where you said you were going to do that, just put it down to my stupidity....
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Old 08 September 2005, 03:54   #69
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Excellent job
I love the seating
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Old 08 September 2005, 10:48   #70
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Ooh, can we take her out now? Chuck a battery in, a portable fuel tank and some rope tied to either side of the outboard to steer with and voila!

At least you'll know if you'll sink or swim! Can we? Can we? Go on Tim .

Have to arrange to have those Seat backs delivered to you Tim. I might be out on the water this weekend as I'm having the engine stripped and serviced tomorrow to sort my problems.

Andy
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