A Glass Hull

We flipped the hull over today so that we could sand and glass the exterior.

We expected some squeeze-out along the joints and at the holes. We didn't expect to see a near perfect tongue depressor formed from epoxy thickened with wood flour.

It didn't take long to get rid of the squeeze-out, sand the hull, and radius the keel and chine lines.

We had a few spots that we knew we'd need to add a bit of thickened epoxy to fair the joints at the bow and the stern. After that, we laid out two layers of fiberglass fabric. The inner layer extends about 2 inches above the chine and then the outer layer goes past the shear.

I started near the center of the hull and worked towards the back, using a credit card for a squeegee to spread the epoxy. After wrapping the glass at the stern, we used a piece of plastic wrap to keep it down tight to the curve of the keel until it cures.

Almost done - just the final section at the bow.

As done as it's going to be for today. Tomorrow morning the excess glass will be trimmed from the shear and then we'll be ready to put it back in the cradles on the strongback so we can start stripping the deck.

One of the final steps of the kayak construction project will be to paint the hull Hatteras Off-White.

If we're on schedule, we should be camping near Shinumo Wash (river mile 29.5) when this is published.

All Packed Up

As this is published, BJ and I will be at Lees Ferry on the Colorado River, downstream from the Glen Canyon Dam. The day will have been spent rigging and loading three dories, four 18' rafts, and an 18' cataraft in preparation for my departure on a Grand Canyon river trip for the remainder of the month. My pile of gear wasn't as big as it seems - the white footlocker on the bottom of the pile didn't go.

With the chance for a once in a lifetime trip, it was time to replace the camera that died at the end of last year's Alaska trip. This time I went with a Fuji X-S1 because of the manual zoom which should give it longer battery life. Two spare batteries for it and one spare for my very tired and no longer waterproof Olympus Stylus 850SW go along as well. The bright yellow Pelican case should keep it dry in normal circumstances.

Even Squeak got some new gear. I couldn't find a PFD (life preserver) that would fit him so BJ provided him with a leash. Squeak represents all the friends who wish they could join us on this trip.

There are several more posts about the kayak project that will be automatically published while I'm gone, but a trip report and the final steps on Kathy's kayak will have to wait until I return at the end of the month.

The Shape of Things to Come

We had two goals for the day - figure out the correct size and shape for the permanent forward bulkhead, and create and install temporary spreaders as necessary to hold the hull shear line to the proper beam while maintaining a fair curve at the shear line. (The shear line is the top edge of the "stitch & glue" hull.) Kathy went to work marking the center line on all of the deck forms.

It took all morning, but we got the bow and stern temporary forms as well as all of the deck forms properly positioned to maintain the beam, curve, and lines for the deck. Then we cut several spreaders and glued them in place with hot glue.

We put it off as long as we could, but it was finally time to determine the size and shape of the forward permanent bulkhead. It had served as a temporary bulkhead at station 4 (feet from the bow.) There was a deck form at station 3.5 and another at station 4.5. The permanent bulkhead needed to be at station 3.75. Lots of calculations to extrapolate appropriate dimensions.

Forward bulkhead positioned in its final location. You can see the spreader sticks that we installed as well. The forward bulkhead was held in place with three dabs of hot glue, and then filleted and glassed in place on both sides of the bulkhead.

This is the view from the "moaning chair." (Every project needs one!) We've scarfed and joined lengths of Honduran walnut together to form two long strips that will become the outermost (shear) strips for the deck. We removed all the deck forms from the bow and stern hatches, but left the center section forms in place. If they stay in place when we turn the boat over, it will save a bit of future work. Next step is to flip it, and then sand and glass the hull.