Simon,

Carbon Fibre centreboard cases ! <img src="http://www.catsailor.com/forums/images/graemlins/cool.gif" alt="" />

You would only have to worry about the surrounding structure and not the cases if you ran aground.

Regards,

Peter

That must be why I go sooooo fast! <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" /> <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" /> <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" /> <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" /> <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" /> <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" /> <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" /> <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" /> <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" /> <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" /> oh, and <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" /> <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" /> <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" /> <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" /> <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" />

So what stage are you up to Simon?

I have left you alone for 2 weeks - 1 was out due to holidays, how about this last one?

Trevor

Hi Trevor,

I've been a bit slack but have progressed. I seem to have fixed that problem on the inside near the front beam where the tramp had pulled the ply away a bit. It don't think it was too serious as none of the epoxy came through to the inside when I injected it. I found a cheap large clamp at Bunnings that was big enough to negate the curve of the deck and it seems to have done the job.

As for the big job! I had some practice goes with varying mixtures of epoxy on some scraps so I could get the feel of things, and have now taped in the foam around the case that was loose. I had a bit of trouble getting a nice straight edge on the hole without cutting into the stringers but have now got it pretty neat.

Getting the frame from the bodgy repair out was a bugger of a job with all that bog.

I'll do a bit more this weekend but next weekend I am kid free so I plan to get a fair bit completed.

I've got my timber for the new stingers and frames but still await the arival of my 3mm ply.

I'll post some more photos after the big weekends work.

Cheers,

Simon

Hi All,

Repair nearly finished but I have been filling in the "Curing Time" with fitting some new boards.

Question:

With the new boards seated in the correct position against the back of the case I now have a 2cm gap (tapering to nothing as you move aft) on the bottom of the hull. What is a good "fast" method to fill this and how crucial is the fit. (i.e. how tight should it be?)

All tips welcomed.... I'm running out of time <img src="http://www.catsailor.com/forums/images/graemlins/blush.gif" alt="" />

P.S. I have spoken to the weather gods and have been assured that the winds will be perfect for the Cat Classic this year (Nov 1-2) Apparently all I have to do is sacrifice a virgin under the light of the next full moon.

I tried this method for last year but I guess she must have been telling fibs. <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" />

Hope to see lots of Mozzies!

Cheers

Hi Simon

I think the method is to turn the boat upside down, put the boards in with one or two layers of plastic shopping bag wrapped around them where the board meets the boat. Then you push some thick epoxy filler into the gap and wait for it to set - make sure the boards are pointing straight forwards while the epoxy sets.

Take the boards out and fair in the filler.

There may be other refinements to this process - I've only replaced bits of filler like this. I've never done the whole lot.

Most Mozzies seem to be done this way, though I wonder why more are not set up with a much bigger gap between the board and the case (like 2-3mm) so some sort of hard felt or similar material could be put in there. This would surely end up putting less scratches in the boards. Anyone know why Mozzies don't do this?

Thanks Tim.

Hi All,

It's very quiet in here so I thought I'd do an update on my repair.

I have replaced and or reglued the foam frames around the case and completed the rebuild of the section. I made two 4mm ply and balsa wood sandwiches as short frames on which to join the stringers. Then replaced the thin foam frames that were there with three 38mm foam frames.

I'm hoping this will be much stronger than the original but hasn't added too much wait.

I glued the deck piece on tonight. Had some dramas there as those who know the boat might recall that the track for the tramp is inset into the inwhale to work in the same fashion as the glass boats. I learnt an good lesson at an inappropriate time..... Copper nails will not hammer through aluminium track <img src="http://www.catsailor.com/forums/images/graemlins/blush.gif" alt="" />

Here are some happy snaps of the internal structure.

I'll post some of the deck in place when it's dry and I've had a chance to tidy it up. <img src="http://www.catsailor.com/forums/images/graemlins/shocked.gif" alt="" />

I still have fitting the new boards to complete and of course a bit of painting.

I hope to be back on the water by the weekend after next.

Not sure I'll be chasing a career in boat building <img src="http://www.catsailor.com/forums/images/graemlins/confused.gif" alt="" /> but it has been an interesting learning curve.

Thanks to those who have provided valuable advice during the project. <img src="http://www.catsailor.com/forums/images/graemlins/grin.gif" alt="" />



Cheers

and another

Hi Simon,



So did you just keep hammering anyway ??? <img src="http://www.catsailor.com/forums/images/graemlins/wink.gif" alt="" />

Is that a doona and matress in the backgroun for you to sleep on ? <img src="http://www.catsailor.com/forums/images/graemlins/laugh.gif" alt="" />

Regards,

Peter

Hi Peter,

Nice to see you back on line!

I reverted to stainless screws. I never liked them on the inside of the deck and was hoping to do away with them. Now I know why they were there <img src="http://www.catsailor.com/forums/images/graemlins/shocked.gif" alt="" /> If I'd thought ahead I could have drilled small holes for the nails but alas the glue was on and I had the other side nailed.

Any Somers lads coming to the cat classic this year?

Cheers

looks good, see you at the cat champs.
on that who is going to the cat champs would be good to sail against some mossies some time, every time i have been out this season it has been against fleets of Tiapans.

Simon,

Good to see it is nearly all done..and now for the fun part, the centreboards.

I have now done/or had done several sets and not hard, just care to be taken.

If you want the way i did mine drop me a line and will send you the details, I am not home until end of next week, (at sea) but happy to help from then, might even get out for a sail myself.

Basically as Tim described it a while back but I use a lot thicker plastic sheet and a slightly easier way of stopping the filler running down the inside of the cases and making a bigger bloody mess than needed.....enjoy either way and maybe we will see you at Wallaroo.

David

Hi David. Yes nearly done. I've posted a photo of the deck piece done with one coat of paint thus far. 2pac paint is a harsh judge! but not withstanding the fill job, I am very happy with the strength of the deck. I was planning to wrap a board in multiple layers of cling wrap for the bog job. Seemed like a good way to ensure no leaks. I did a test to make sure the epoxy doesn't eat the plastic and it all looks good. As for the bog bit. I am going to do it from underneath. With all the various pots I've mixed thus far I have noticed that using Micro Balloons as the filler rather than talc you seem to be able to get a really good paste whith virtually no sag. The pot life is a bit short in this state but I plan to do one at a time and perhaps some masking tape to make sure. Cheers Oops! can't see where you upload a file in the new forum. Photo might have to wait.

Hi There

When I did mine I used brown packing tape on the board around the area in question, a couple of layers would be fine.

I held the boards in position by inserting packers using slithers of timber I had around.

Turned hulls upside down then carefully pushed some styrofoam cut into long thin wedges to match the profile of the board, then I filled in around the board with the filler mix not too runny and not to thick, the foam stopped the filler from going through too far, and when I tapped out the board, you can break out the foam, even if it leaves a bit in there, it is clean itself out eventually pulling/pushing the boards in/out.

I hope thats sort of a clear description.

Regards

Here's the photo I mentioned.

Boards going in tonight. Thanks for the tips guys.

If all goes well with the boards I'll hopefully get the paint finished in time for a sail this weekend

Cheers

Nice work Simon,

Its good not to be able to see the insides again!

Trevor

Thanks Trevor.

Here's a photo of the finished result with new board in place.

The finish is not as neat as I would have liked but frankly, I just wanna go sailing! I am putting every thing back on tonight and will be on the water tomorrow. Yippeee!!

Hey Trev, I reckon you should have some news by now????

Cheers

Hi All,

I found the cause of my deck cracking probs. The ply has pulled away slightly at the inside of the front beam (see attached photo) and as it flexes, it cracks the deck and lets in water. I was going to leave it till winter but I took on a fair bit of water in Saturdays "fresh" conditions so I thought I'd fix it before the states.

My thoughts are to use a syringe to get as much epoxy in as possible and then clamp, followed by a tidy up with some filler on the deck cracks. Will this do the job or is there a better method?

Cheers

Simon,

Good to see that you found where the water was getting in.

It looks like it is water saturated or is that just my imagination. You may also need to consider using everdure to penetrate the ply then epoxy the joint.

Regards,


Peter