1763 Deck Re-build

Evening all,
The last few weekends have been spent re decking Simon Bone's 1763 as the rear decks have flattened out and cracked around the centrecases. The original [AJ] construction method was longitudinal stringers set into foam stations with ply only at the beams and centrecases. Over time the foam had compressed under the decks separating from the stringers/deck undersides/hull sides. The deck hull join was still intact but the deck was flexing downwards spreading at the foam /hullsides join.A trip up to Duck Flat Wooden Boats for 4mm Gaboon Marine ply/glass/ Bote Cote epoxy, rollers, and some expert advice. We routered the decks off and cut some ply stations [7 per hull] to add strength and ripped up some stringers from some cedar.The port hull was in better shape than starboard with the stringers [5] reasonably intact, the starboard stringers were all broken aft of the centrecase.Scribing in the 100 mm deep stringers to the hull sides/stringers was time consuming but essential. Today we fitted the decks with epoxy/ temporary stringers in what was reasonable temperature with the last couple of weekends being a less than ideal epoxy temp of 12 degrees,
Cheers,
Roy,
1770 Rebel Without a Clew

What have I started

Good to see others doing similar repairs


How's the Vale these days, been a couple of years since I've been "home", lots of family in that area.....

Kingy

Hi Kingy,
Biggest change recently is the flyover into the Vale on the Victor rd/Main rd junction, lot safer. On 1740 were the foam stations separating from the hull sides? It sounds like they were, the tops of the foam in 1763 look very similar to yours. With the starboard deck off we were able to lift the stringers [what was left] away from the foam stations. I took some pics during the rebuild and will post some up. I took a slightly different tack to holding the decks down,
Cheers,
Roy,
1770 Rebel Without a Clew.

yes the foam stations had separated from the hull sides but at different degrees and in a patchy way..... not all of them had let go and whilst a couple had completely become detatched others had only slightly let go, I also had a couple that had cracked across the actual foam and yet were still well attatched to the hull.

I think what happens is the glue at the foam/deck/hull connection area is under constant stress, weight on the deck pushes down and therefore this pushes the hull sides apart, once the glue begins to fail the foam subframes begin to compress, this inturn allows even more pressure to be placed on the hull side and so the glue continues to fail further downwards allowing even more foam compression/failure....
once the stone starts rolling effect

be interesting to see your approach.....

I have been doing this thread butt about face, must be something to do with taking images of the re build with a phone instead of the camera then finding it did not come with a cable to connect to the computer[cable available for $40]Naturally, it is also not compatible with any of the multitude of cables we have in the big box under the computer desk,
Anyway, here are the first two images taken of 1763 after the removal of the deck............basically it meant the job just got bigger!
Cheers,
Roy,
1770 Rebel Without a Clew

the failures are almost identicle to mine....

I see the foam has had the top section replaced already somewhere along the line


otherwise the construction of your hulls is scaringly similar to mine..... even the conduit for the trap is set in the exact same manor and position as are the actual subframes....

Yeah, at least one of the decks on 1763 has been replaced at some previous time as there was evidence of repair. AJ/Brian built a succession of boats 1740/1762/1763/1771/1777 That probably is not all of them, successive boats being slightly different to the previous with some ideas being typical to all,
Cheers,
Roy,
1770 Rebel Without a Clew.

Hi Roy,
Following this rebuild with interest as with Pirate's rebuild. Where your entry lists 10 or 7 downloads and I can only open one, is there a process I am not undertaking to see all the images?
I am learning a lot about how this generation of boats were assembled. Simon's is the 3rd redeck I have studied in the last 18months. Gleaning great detail!
I shall begin my own forum in detail when sufficient info generated and I learn how to add pics.
Thanks for the pics. guys

I wonder how many of them have had the deck issues we've experienced ???

Kingy

All of them! And more issues as you have experienced. Maybe not 1777.

As a one time owner of 1762 I concur. I've come out in cold sweats on occasion watching your progress Pirate. Oh the memories, Oh the horror, Oh how I love my foam sandwich boat! Clearly you have considerably more skill and patience than me. I tried hard but confess I just gave up in the end. Thankfully Simon put the effort in to save her from the fate I had in store for her.

Cheers

I didn't have grey hair 2 months ago

"I didn't have grey hair 2 months ago "
I found my first grey pubic hair the other week..............in a spring roll!
Cheers,
Roy

thanks for that "image"..... & I'd just had tea....



I work in the steel industry so doing a wooden boat repair when the closest tool I have that's related to timber is a pro chainsaw is certainly a bit of a leap of faith.... having said that.....
I've thoroughly enjoyed every minute, except for the staples bit


& yeah I'd do it all again

In order to tie in the hulls/ deck/stringers/etc we made up some ply/glass stations which were bonded in to form a strong setup. A string line down the centre was set up so hull measurements could be checked to be equidistant as we did not want the bloody thing to sail around in circles!
Cheers ,
Roy.

One of the factors of re decking Simon's boat has been that he is a dairy farmer down at Yankalilla and I live at McLaren Vale [40+km's]so he comes Sat/Sun to work on the boat between the morning and afternoon milkings! I know when he is just around the corner because the temp plummets and it rains!
It was cool when the decks were epoxied on so we left it for a few days prior to removing the temp fixings, no issues so the excess deck was trimmed away, dagger board slots and hatches cut out and two coats of epoxy applied [still raining!]
Cheers,
Roy,
1770 Rebel Without a Clew

Sunday morning with the epoxy hardened I set the hulls up in the drive ready for Simon and beaming up.There is something about a dairy farmer straight from the milking shed which is irresistable to Billie the Retriever. Especially the boots!Pic 2 this is about as far from Simon as Billie got. Talk about Bromance!
Awkward beam setup, Simon got his arms stuck in the rear hatches,I got mine stuck in the front,fruity language did not help either, captive nuts set into the hull beams would have to be the way to go,
Cheers,
Roy,
1770 Rebel Without a Clew

Beaming up took a lot longer than it should have and we only just made the 3pm deadline for Simon to make the afternoon milking. Still, the end result was good, we were not chasing minimum weight as much as strength, the deck should last as it is rock solid. Simon likes the timber finish and will apply a clear coat over the epoxy.........Billie is still waiting for him to return!,
Cheers,
1770 Rebel Without a Clew

always looking for new ideas .....

post em up

I think you will find JAKEA is a scam of sorts, he has lifted some text from one of the posts I put up regarding Simon's re deck........then there is a link to whatever it is he is trying to peddle. I received an email notifying that I had inherited 3.5 million Euros from a long lost Uncle in Ireland [ don't have any relatives in Ireland!] Googled Earthed the address and the streetscape was a pawn shop and an Indian take away in Belfast [Northern Ireland has pounds not euros!]
Cheers,
Roy