Farrier F22R trimaran building blog by Andrew McLeod

Christmas and New Year Update

2012-01-23T15:24:00.000+11:00

Progress has been slow lately as there have been some other projects to be attended to, but first the boat.

The windows arrived late last year from City Plastics in Adelaide and this allowed me to cut out the window openings with confidence that I would not have to patch the holes later. It certainly changes the look of the boat and makes it more aggressive.

The beam mounts have also had their final lamination completed, this now leaves the "builders discretion" parts to go as the plans are basically complete for the main hull now.

Finally the mast steps have been completed. Here the 3 are set up ready for delivery to their respective owners. Thanks goes to bale engineering for their assistance with this build.

The summer holidays called for a Pizza Oven so one was built, tested and ticked off the list of things to do. The basic construction was using common house bricks, works quite well.

The other major project has been the chook house"la coop". This work of art is also featured in my other blog bokboks.blogspot.com where the lives of our chickens will be posted.

Poop chute

Finally some pictures from the Manning Marathon yesterday. The race was a very wet and windy affair with gusts over 25knots.

Some had a bit of trouble in the de-rigging area.

Line honors winner Mark Braithwate and his daughter crossing the line.

Corsair 24 motor mount, nice idea for mine.

Ross 780 making hard work of it.

Cockpit coamings continued....

2011-12-22T09:00:00.002+11:00

One of the challenges with the cockpit coamings appears to be how to hold them in place while they are curing. Here is how I did it.

For the front half top, I have a pre-cuts panel from ATLComposites. Only problem is that they are not bent for the curve of the coaming and was too stiff to be held in place. I though about how I could force it in place but decided in the end to strip the carbon from the back of the panel exposing the raw foam. This allowed the panel to flex significantly more as the foam stretches around the remaining layer of carbon.
The next challenge was the gluing flange. This has been a bug bear in the past as the carbon is very flexible due to the fact it is very thin. Great in tension and compression but it won't really stand up without something to assist it under the pressure that is normally applied when gluing. I made 2 piece polystyrene molds, wrapped in packing tape for the inside of the coaming and laminated these with 2 layers of carbon, 1 to replace the removed layer and one for the flange. This was then propped up from underneath with batten offcuts internally whilst the resin had not tacked off. I then applied a microfibre and resin mix to the underside of the panel and then put it in place, secured through the edges with screws into the exposed foam edge. As this will be sanded away later to form a rounded edge the holes should not pose a significant problem structurally and will be filled. I let this cure and set to work on the back section. The internal molds and battens were then removed leaving some sharp edges that were trimmed whilst the resin was still green.

The rear coaming half is a different beast altogether. I should have fared the undersides of the opening prior to installing he cockpit seat and builders should examine step 6 on Sheet 25 for what to do. I wanted to get it all done in one session to avoid the gluing flange issue. The inside front of the coaming was glued and filleted into place first and then once the glue was beginning to tack, the panel was taped into position on the bottom, front and top edges internally. This was simple enough and gravity assisted with holding the part in place. I then glued in the rear panel which has extra re-enforcing on the rear meaning that the screws could not be used to hold this in place like the front coaming top and I struggled for a while and eventually came up with a neat solution. I hooked a tie down strap into the upper folding strut bolt hole and laced it over the panel. I also realised that I should not have removed the peel ply at this stage but it was too late to go back now.

This then runs back into the recess for the lower folding strut, under the hull and then onto the opposite side gunnel. This puts significant force on the job to hold it all in place and I would recommended the same process again.

The hull was rolled over and the internals of the recess were filleted and then laminated to plan. All up this process took about 3 hours to complete and by the time the peel ply went on, the initial glue had gone off, but the laminate was still green and soft. The peel ply is not as good as I would have liked but there are several layers here and it was not possible to see the front panel, I tried to get a peek and almost got stuck inside the under seat area.

This was allowed to cure and this morning Jen and I rolled the hull back upright. I know that other builders will be envious of how easy it is to roll the hull over at this late stage of the build. The eye-bolts in the roof have definitely paid for themselves.

Mast Step, cockpit coamings and mainsheet traveler

2011-12-17T21:04:00.000+11:00

This week has been more about the mast steps than anything else. Thursday saw the end of the work on them as they left to be anodised. They will be back after Christmas, probably the middle of January. I am really happy with how they turned out in the end, the quality of the welding and the material used was top class.

I then turned my attention back to the cockpit coamings. These have been hanging around for a while and needed to get done. The main issue was, what to do with the hole at the end of the coaming. I sent an email to Ian and he advised ( within 2 hours on a Sunday mind you) that it was up to the builder. Others have built small dams to stop water entering the boat from the coaming however I have chosen to mount speakers for the boom box instead, so an alternate solution was required. To prevent the expansion and contraction of air due to temperature changes, I decided to put speaker ports in the coamings to protect the speaker from air pressure caused by heating.

I calculated the volume at between 30 and 36 litres based on a rough sketch of the sides and used CAD software to measure the volume. This was then fed into a speaker port calculator to determine the appropriate size required. I found in the workshop, an off-cut of PVC pipe and applied a layer of packing tape and then laminated 200gsm twill at a 60 degree bias around the tube. This gave an internal dimension of 55mm meaning that the speaker port length would need to be between 1.7 inches and 2.5 inches depending on frequency and volume of enclosure.

The next job was to create the flanged entrance, this is required both structurally and acoustically finish the port entry through the seat. I took and off-cut from the original tube and used Turbo Bog to create a fillet on an off-cut of MDF. The bog is my go to tool for mold making as it sets in about a minute so you can work really fast. Based on the timestamps of the pics, it took 12 minutes to bog and fair the surfaces.

This then had a layer or five of packing tape applied to seal the surface and form a release surface as epoxy won't stick to the tape.

I then used more offcuts of carbon to laminate the flange after putting the tube back on the PVC. These then were inserted through the cockpit seats and tied to the roof to ensure sufficient pressure for adhesion and left overnight to cure.

Today the cockpit coaming fronts were glued and taped into place. Here the speaker hole on the right and wired remote hole on the left can be seen. Through the speaker hole the port can be seen sticking up through the seat as well as the holes for the IP65 wiring fittings to ensure air does not get pushed through the smaller holes. Additionally that pesky hole that started all this was filled with an off-cut from a pannel and laminated over with yet more scrap carbon.

Later this afternoon I bit off the main-sheet traveler. This is probably overkill but I wanted to ensure that the cockpit compression loads from the beams would be transferred across this beam effectively. I laminated uni from under the chine along the valley and down the seat front. This ties the outside and the insides of the cockpit together. I then glued the traveler beam and laminated over it with 2 layers of double bias carbon.

Also during the week the tubes for the wing-net lashing arrived, support posts for the re-designed wing-net rails and the spinnaker pole for the bow. More tubes to come but at least its a start.

More metal shop and netting

2011-12-13T18:22:00.000+11:00

The work continues on the mast base, but the other parts including mast foot and rotation arm, mast raising pin assembly and guide ears has been completed. Initially the water jet cutting marks had to be removed but some marks from the TIG and scratches pushed me to re-finish the whole lot. I set to work with the dremel, powerfile and flap wheel sander and 2 days later, hey presto..... (backdrop is the cockpit seat with the peel ply still on hence the red stripe)

Another delivery today with the Dyneema netting from Lankhorst Euronete Australia. The edges may also be good enough to avoid the lacing on one side near the hull, instead I may be able to use the fiberglass rod and go straight through the netting. Apparently this is the stuff that is used on all of the big multi's and is braided together to form a knotless mesh that is really strong, and you can feel it too. This piece is 100 meshes by 50 meshes and comes priced by the kg and was flown from the US of A in about 8 days.

There should be enough in this piece for the main nets as well as the bow netting.

Metal Shop

2011-12-09T19:50:00.001+11:00

Turned the workshop back to metal today, finishing most of the parts off in preperation for them to be welded next week.

As one of the boats is a center-board version and two are dagger-boarders, there are some differences that allow for the control lines to come up from the top of the dagger-board version. As the water jet cut parts were discounted for as 3 sets, the subtle differences had to be accounted for manually, i.e. I had to do some cutting and filing. Simple enough but I am out of practice so it took a little longer than expected.

Also due to the water jet cutting only working on 2 dimensions, the "ears" that are stepped down also have to be cut by hand ( or CNC if you are lucky enough to have one kicking around).The ears rotate on the bolt ( in the assembled part) to grab the base when the mast is being raised to guide it onto the ball, then fold forward to allow the mast to rotate.

The process of cutting the majority of the excess material ( marked ready to be cut on the right ) is simple enough but requires some metal skills as it is easy enough to stray into wanted material with a hacksaw. Then I used the powerfile to remove the corners and then a bastard file to get it a bit closer. With 3 remaining and a final touch required on all 6, it's back to carbon sometime tomorrow.

Mast Step, more taping and outboard

2011-12-08T14:55:00.001+11:00

Parts for the mast step(s) turned up today. I am in league with 2 other builders, hence the 3 sets and the reduced price. These parts were water jet cut out of 6061 T651 aluminium and have to be finished so that they can be welded and anodised.

6061 T651 Farrier F22 mast parts

The cockpit taping has also been completed. I took the suggestion to use the router to round the edges and it made a lot of sharp splinters, some of which made it in to my shoes. The result looks ok.

I tied the traveler valley into the hull sides with some extra double bias.

The settee is also completed with only some of the edges around the dagger board case to go. I will decide over the weekend if we are going to put more panels into the boat or get it on the water.

The outboard also looks like it will have to be set a long way down. I established the DWL from the plans but I am not sure how much this will change with the lighter boat. I was planning on building an outboard bracked however the low height means that I will not be able to tilt the motor with it at this height as the cowling hits the seat.

Finally the port front external taping has been completed. This was made easier with the assistance of Bryce a fellow multihull sailor.

Cockpit sanding fuel tank and bunk board

2011-12-05T20:43:00.001+11:00

I missed posting about the bunk board and fuel tank, so here is a bit of a catchup.

Last week, I laminated several left over hardwood floor boards together to make the curved bunk-board for the trailer. The glue used was the same PVA glue that I used for the bows on the floats which requires moisture to react. I used two layers of 19mm Iron bark boards which produced the feature below.

I also spent the day routing and sanding the cockpit edges ready for lamination tomorrow. In the process I also cut out the rear beam bulkhead. I wanted to make sure that the hull did not move when the beam was removed and I measured the before and after and there was no difference in the spacing. The cockpit however looks much more open without the beam in place.

I also cut out the traveler sides so that the beam can sit in place and water drain from the seat.

The beam was also tested for deflection and with 87kg in the center, supported at each end, there was 5mm deflection. When supported this beam should provide significant stiffness and support for the main-sheet as well as to keep the spacing of the cockpit correct under pressure.

Sitting in place untrimmed, overhanging the edges of the seat.

I also carved out the ends of the rear beam bulkhead using the dremel. This worked a lot better than I though it would and will definitely give it a try next time. Previously I have been using a slot cutter in a router and this has a nasty habit of chewing through the carbon.

Finally I though that I should share the fuel tank mounts, these are offcut panels glued and laminated into place with carbon tube with uni directional carbon tying it down.

Beam mount exterior lamination, settee and anchor well

2011-12-03T21:16:00.001+11:00

Unfortunately there has not been much going on that can be shown in pictures. Most of the activity for the last week has been about windows, mast base, the electronics and the rigging including mast. Whist there has been a lot done, there is little to show.

The week started with the bow reveal but I only did some catch up pics tonight following the boat being flipped back up the right way this afternoon. From this angle the rake on the bow looks very aggressive, but the boat is not level ( about 6 inches down at the stern ). The laminate looks really good and I think that I should have used 2 layers of twill for the entire exterior, shame it would be heavier but it is a nicer finish and will need a lot less faring.

To install the settee, I had to make a front from the excess panels from ATLComposites. The main victim was an unsuspecting aft cabin panel.

Once I ran it through the band saw a couple of times to cut out the material for the 100mm front, these were glued, and laminated onto the last remaining interior panel.

Total weight of seat and front was 1.91 kg. This was inserted into the hull and held in place by some wooden battens ( but I have only taped it on the bottom sides as they will be much easier to do when it is upright. This shot also shows the passage way flange( the edge of the bulkhead ), now trimmed back to size.

I also completed the taping of the anchor well, and inserted the carbon loop for the anchor line. This was made from a offcut carbon tube with some 30 wraps of unidirectional strands on the load path. Weight before insertion was 54 grams. The eye can be seen sticking out in the anchor well.

It was then laminated into the hull with 2 layers of double bias. I am contemplating using this same technique for some of the pad eyes like the bow nets, as some of these parts are $100 each, yet these can be made literally from scraps laying around the shed. The process for construction of these is simple and the can not leak unless the entire part fails. Also there will be no condensation forming on these parts as the majority of the part is foam. The bottom surface is the front face of the anchor well and the rear of the shot is the underside of the foredeck.

By far the most exciting was the exterior lamination of the beam mounts. This was easier than expected however the prep time was quite long, the process and results are good. I would recommend doing the bottom half upside down as the laminate was easy to apply. For the front I only used 2 pieces of carbon and was able to cut some relief into the cloth to allow it to sit better. I added some small bits for the rear side of the mount and these did prove to be challenging to prep, but easy enough to laminate.

For the rear, 6 pieces were required because of the deeper cut out but the process is essentially the same. I overlapped the carbon on the sides continued it to the top of the cockpit side. There is additional laminate required once the coaming is installed and will have to do that next. The safety compartment also got a layer or two of carbon to seal the exterior surfaces and can be just seen above the rack.

Finally here is a look from the rear, mainsheet traveler beam is just sitting there as is the coaming sides but it is looking a lot more like a boat, and you can still lift the transom with one hand.......

Bow Laminated

2011-11-23T17:30:00.001+11:00

The bow has been a sore thumb since the exterior lamination. Due to the additional pieces like towing eye and bobstay eye, it had to be left out of the main hull lamination. With the boat upside down and these pieces complete, it finally got it's turn at the top of the priority list.

Initially the bow was blunt and I added the green Airex foam as per the specifications, with the exception that the rake of the now matches the floats. As the floats were a bit of a "suck it and see" with the concavity and as a result I was unsure how much the additional rake required to be filled in the main hull.

I added a small piece of corecel each side ( beige foam over the top of the holes) to reduce the required fill, but there will be some more required as it was not big enough. Once the holes were re-cut and the cut-outs for the "hard stuff" where the trailer rollers and the bobstay lashing rubs, I filled and then laminated the exterior of the bow.

Since the weather has got crappy again, I will have to turn my attention to other matters that do not required epoxy, like windows and mast base.

Rolled over, cockpit seats et al

2011-11-15T21:13:00.001+11:00

Today, with the help of Bryce ( fellow multi-hull sailor) and Chris ( fellow F22R Builder) I flipped over "the girl" as my girls are calling it. All pictures however have been rotated back to upright to keep some sanity for the viewing public.

As you can see from pic 1, she is very light, here being strapped to the floor ( of upstairs) so that she does not hit the roof ( of the upside down downstairs). Rolling her over was quite a simple process, I commonly use tie-down ratchet straps to lift her from the cradle and then turn her over. I was concerned that the additional weight since last time would damage the cockpit coaming but we were able to lift her over the pressure points and use the Upper Folding Strut (UFS) bolt holes to lift her.

I was able to fit one of the cockpit seats, this was a somewhat difficult process mainly due to the cockpit being just too high. I am confident that the tape has worked properly and have just about given up on making flanges to glue against ( the coamings will be a test though as I am unsure how I am going do do them without making flanges) Here is the underside of the main sheet traveler valley against the outside of the port hull.

Probably the nastiest area to work has to be inside the 3/4 berth foot well. This houses one side of the rear UFS bole hole but only has one opening to speak of. The fumes in this area from the epoxy were significant enough to get the compressed air and re-fresh from the stale compressor air for relief.

I am quite happy so far with the seats, they look the part and are light. I suspect however that the total mass of the boat is now approaching 160kg.

Just to show that it is not all easy going, here is a pic that shows how crowded it is.

Ok a bit of a catch-up.

I ordered the front hatch from www.e-marineworld.com.au and for the second time have been blown away by the price and speed of delivery. 22hours from order to delivery.

I also was catching up cutting out peel ply and was greeted by a huntsman spider, presumably he was in the peel ply roll. Nice pic though for an old camera.

Passageway flange, anchor well and safety compartment

2011-11-09T20:40:00.000+11:00

The reveal on the flange was a spectacular surprise. The flange appears to have no bubbles or gaps at all. I was really surprised as the challenge of doing it blind was added to the additional heat on the day, however I will bank that win as I am sure it will get used up somewhere.

Taking that one back out of the bank, the anchor well had to be extended beyond what seemed to be a "simple" build. It appears that the plans are misleading in that they say " 4 frames 300mm apart" but does not specify a length required, one would assume ( Ass out of u and me as they say in spelling tests) that it is therefore 4* 300 + 18mm wide, BZZZ, wrong answer. It needs to be 1134 wide???? Solution - make some more, cut it out , add it to the sides, yet laminate more carbon to it...... presto a nice anchor well. I also cut a slot for the fitting to take the tail end of the anchor line in the front edge.

I also put in some overtime and fitted it to the boat. It seems to be quite shallow so there will be no 10kg danforth and 30 meters of chain in here.

I also consumes more space that I pictured ( and the boss pointed out). It is propped up here with the cut outs from the cockpit and some left over battens from the mold.

I also dug another hole in the boat, this time for the safety compartment. I will add another layer of 10mm foam ( an offcut from the boat bulkheads) over this hole to form a flat area and recess the hatch so that there is no chance of damage from the floats.

Demons conquered

2011-11-07T20:23:00.002+11:00

Since I first studied the plans, there has been one process that I have looked forward to with dread. This is effectively a very long flange that is done almost blind due to the angles and forms a critical part of the structure supporting the front beams. It is called the forward passageway flange and it effectively stiffens the main beam bulkhead to prevent it from twisting under load, considerable load. I cut the carbon on Saturday and had it all ready to go but installing the mold and prepping the surface took some time to complete. For the resin, I used the Kinetix R246TX laminating resin from ATLComposites giving longer working time than the West. It is impossible to take a picture of the laminate as it is wrapped around the outside of the MDF mold. The laminate is effectively 8 layers of uni and some double bias to tie it altogether. I was able to put peel ply onto the job and hopefully compacted it properly. We will see in a couple of days how it went.

I also tackled the main-sheet traveler. The laminate was also cut previously and there is a lot of laminate. I used almost 1kg of resin and decided at the last moment to bag it as it was getting out of control. There is, as a result, a substantial amount of resin sucked into the lines this time. I have not been this wasteful with resin since some of our jobs almost 18 months ago.

Companionway and main sheet traveler

2011-11-06T19:50:00.004+11:00

Now that the companionway is open, the edges need to be addressed. First cab off the rank was the foam lip around the top. This was a problem as I had to make up some 20mm foam and the scraps that remained only stretched to 3 offcuts. It is worth mentioning here that the plans call for 10mm foam and then assume that the builder will make 20mm from that, BIG MISTAKE, if you are going to build one of these, get 20mm. Simple enough process, cut the lip out and glue it on.

I also took the opportunity to start on the main-sheet traveler. I was in a discussion with another F22 builder and we were discussing the differences between through bolting and using an embedded plate. After cutting all of the required laminate, the aluminium plate is nothing compared to the weight of the raw carbon. Here it is prior to assembly, the aluminium plate can be seen on the rear saw horses.

And initial assembly completed wrapped in masking tape. I also put a layer of fiberglass over the aluminium to insulate it from the carbon.

Anchor well, cockpit seat fronts and hatch cutout

2011-11-02T21:05:00.000+11:00

Over the last few days I have been busy doing multiple things so it is time for a bit of a catchup, first the anchor well. Initially the anchor well requires a male mold to be constructed. This is a simple MDF shape 4 times over the space of about 1 meter. Foam is then bent around the back ( the larger side) using heat and the front is glued using a microballons and resin mix. Simple enough.

The the exterior is laminated and then once cured, the job can be removed from the mold.

For the inside I added a layer of fiberglass to toughen the surface against the anchor and chain, this will prevent it from ending up in my bed hopefully.

Various parts are also coming together (or apart as required) including the cutouts into the cabin from the cockpit. These are to allow access into the underside of the cockpit seat as storage. Here the last of the taping on the seat fronts can be seen.

Also cut out and waiting to be inserted is the safety compartment. This is required to store flares and other safety equipment in the event that the mast is pointing down. There is an additional hull required in the exterior of the hull that has yet to be cut.

I have also cut out the hatch entry way, and I am not sure why I have not done this sooner to be honest. There is so much more light and it is much easier to get into the boat.

Hobie 18 old school

2011-10-30T06:49:00.000+11:00

Fixed a mates Hobie 18 today and took it for a blast. Cut a bit of a vid together, enjoy.

Cockpit seats

2011-10-26T18:10:00.000+11:00

Set to work on the cockpit seats and fronts, with the inclement weather yet again closing in, cutting seemed like a good idea.

The main aim with the fronts was to provide space to allow storage of the fuel tank for the outboard as far forward as possible but not to cut to much structure away from the mainsheet track.

More beam mounts Part 2

2011-10-24T21:36:00.000+11:00

So here we are some weeks behind schedule but happy still with the progress. The complexity of the structural components and the accuracy desired has increased the required time to complete the work. Since the last update there has been some significant work but little to show.

The port cockpit seat cured and was released from the mold but the carbon appears to be dry in a few spots.

The re-enforcing pads for the front beam mounts were cut out. These were made from 73 layers of fiberglass mat over 3 sessions. They have also been glued and laminated into the main beam mounts per plans and take the load from the main beams and distribute it onto the main beam bulkhead.

Rob's moth also left the workshop having been repaired. Looks a little small on the farrier trailer though.

The second of the cockpit seats was laminated today however there appears to be a leak around the traveler channel and I think that I will have to repair it. I have would up the pressure now that the resin has tacked off but will see what happens.

The final hurdle for the cockpit panels was cleared late today with the additional uni across the floor being completed.

The extra resin went into the next job, rudders for Dave's Hobie 18.

Cockpit seats and bow

2011-10-17T18:45:00.001+11:00

Work has been progressing on the F22, most notably has been the cockpit seats and bow. The remainder is more of the same lamination and re-enforcing so not much to add there. Ian Farrier posted several launching updates in the last day or so, here is some inspiration for what is to come. Other information can be found on the F-boat site http://www.f-boat.com/recentnews.html

The bow was an interesting one with a deviation from the plans in a small way with the use of a hole to replace the towing eye in the bow. The insertion of the towing eye finally happened and was quickly covered by lots of peel ply, so not much to look at.

Following that however the foam for the bow could be attached and an offcut 20mm slab of foam from the cockpit seat foam was attached to the bow so the final shape could be made. Here both eyes can be seen.

The cockpit seats have been taking a while with the first finally being laminated up today. The process for constructing the valley to take the traveler has been a process and a half. Also the foam prep has taken a bit with at least one mistake costing half a day.

Here the core sits approximately in position with the gap in the foam ready for the valley. There is also a slot required for the lower folding strut to be cut once the seat has cured.

Typically the laminex sheets that I have were to short so I had to join them to allow for the length of the cockpit. I also added the bricks to stop the twisting in the part with the plastic pulling tight over the panels.

Here is a close up of the valley( upside down ) , hopefully it will be ok.

Some Sailing for a change

2011-10-10T18:27:00.000+11:00

Went sailing on Sunday and tried out my new GoPro camera. Here is a short clip of the spinnaker work using a new mast head Farr 40 spin. The race was a nice distraction from the rain and the boat building.

Cockpit Seats and Port Aft Beam mount

2011-10-05T20:24:00.000+11:00

With the rain and humidity upon us again, I decided to divert attention away from the beam mounts and onto the cockpit seat. This component was not constructed by ATLComposites as it is both 20mm and 10mm thick and their process can not produce panels that are of different thicknesses.

The process for measurement and cutting is simple enough however I decided to do a recessed traveler into the cockpit seat so there are 2 molds required for the "wedge" and these can be seen towards the back of the foam. Despite the simple appearance, they took a long time to cut out due to the 30 degree angles for the sides as well as the slope in 2 directions.

The port aft beam mount went in today as well. Construction of the mold plates was done some days ago however the additional lamination in the beam mounts ( seen here previously vs with the cockpit panels in place and the additional laminates on the white mounts ) caused some re-work of the molds.

Before

Virtual

After

The mold plate is a 5 piece job with lots of packing tape for release. The laminate schedule includes unidirectional to the seat edge on the floor but for some reason the plans were 125mm to short in the laminate length.

Internally the coaming again has a neat line sloping backwards albeit with a few more returns.

More beam mounts

2011-10-02T20:39:00.002+11:00

The process of installing the beam mounts is quite simple, however somewhat time consuming as I have discovered. The initial placement of the mount is one thing, keeping it located correctly and then adding additional laminates is a time consuming process to say the least. Despite the simple process, getting it just right and aligned perfectly is starting to do my head in.

Onto the pictures

The inside Starboard front, this one was a lot better to do having practiced on the Port however the hotter day meant that it was a real workout. The laminate was going off on the rear half as I was completing the front as the ambient temp was about 28 deg C.

And the final laminates onto the bunk top.

Here is the view from the outside. The placement of the external mold was a lot better with this side and as such this is it's "best side"

I have also completed the lower folding strut mold areas under the mount on both the rear mounts. These are a lot easier to work on due to the fresh air.

I have commenced the mold plates for the rear sides and as it is raining today and more tomorrow, I will have these done and ready for Tuesday, hopefully having the cockpit seat foam cut out.

The external laminations and final re-enforcements are also wanting with a week ahead of more epoxy madness. Oh and just for fun I did some 3D CAD of the cockpit.

Sheet 22A main structural lamination

2011-09-22T17:53:00.001+10:00

Today the Port beam mount finally was laminated into place. The process called for several layers of double bias, uni and because it could not be vacuum bagged, lots of laminate compaction.

The mold plate looks a bit agricultural but it does the job. It took far too long to get to this point and there have been lots of questions and indecision along the way.

Here is the rear side of the port beam mount. Note the uni running diagonally up to the cabin top.

And here is the front. This side was significantly less complex with fewer returns however as the initial coat was really tacky, and in the process of placing the first layer of cloth, I destroyed it had to add additional to cover for the loss. Note the uni running across the bunk top in this shot.

Just to add to the fun, there is more than one project going on at the moment....... A Mach 2.

Sheet 22 - Forward beam mount Lamination.

2011-09-16T18:20:00.001+10:00

After much deliberation, leveling and consternation, I think that it is all ok.The Beam mounts need to have an additional flange similar to the rear added under what will be eventually the location that the beam bolts go to retain the beams in the locked down position. The whole process requires multiple layers of double bias and unidirectional cloth and due to the complex shapes it is not easy to get the peel ply to sit down when in one piece.

I was able to clamp what is effectively the "bridge" between the mount and the hull to ensure that the laminates were compacted and stayed suspended and did not fall off. Once cured the end result looks quite good, even if from the exterior it is a little under whelming.

Next we fitted the mold plates for the underside. These required a small amount of force to level however the starboard side needed to be pulled forward to ensure that the fore triangle is the same on both sides, give or take 1mm.

Once prepared, the laminate that will form the lower beam mounts could be applied. The process is quite simple however the plans are not always that specific and some head scratching was really required to work out where the recesses were required and where the fill is needed to go. Here is the rear starboard side.

The forward sides were significantly harder to do because of the extension out of the hull to meet the mold. I have also left the alignment jig in place to ensure that the position of the mounts is retained and correct.

Beam Mounts

2011-09-12T21:48:00.002+10:00

Well I am not sure this is good or bad news, later posts will tell.......

Today we ( Dad, rob and I ) put the beam mounts into the hull, all went well .......

Problem is the port front seemed to be high. No idea why but it is external to the hull and up from the frame. We spent 2 days trying to work it out but have no idea why it is both sticking up as well as off the frame.

Time will be the ultimate test however as the resin is going off and locking it in place........

Holy boat BatMan

2011-09-10T22:44:00.001+10:00

Today more cuts were made and some larger holes appeared. I was expecting that there would have been more movement when the rear beam mounts were cut but the carbon must be really stiff, this is looking like a great boat.

The rear beam mounts needed an additional piece of carbon added to extend the mounts, and whist this was one of the only jobs done yesterday, it needed to be done. Cutting the rear beam mounts was a simpler job than the front ones, mainly due to the ease with which to look inside to see where you were up to. Once cut out, the rear beam mounts were assembled into the jig and placed into the hull. I progressively cut out the required area and it seems quite a waste for all this nice bulkhead to be basically cut up to allow the beam mounts to be fitted into place.