Once this filleting step was done, I painted the entire interior with a diluted epoxy sealer two or three times, to the point of rejection. The product I used was especially designed for this, E Bond 106 Polyamide Epoxy Coating from E Bond Epoxies in Ft Lauderdale. It has an extended pot life which you can extend longer by keeping left over mixed product in the freezer. So, now if water gets into the bottom of the boat, it just sits there on top of this coating and doesn't moisten the plywood. The entire interior will also be painted with Sherwin Williams two part Tile Cladxyed epoxy paint once each part is completed.
Centerboard is constructed. The basic frame is 2x6's glued on edge. Then a hole is cut for the lead ballast and first layer of plywood is put on one side, the three 50-lb weights inserted and epoxied in. Then a layer if 3/8 in ply over that, then one more layer of ply on each side. Shaping to a foil profile as you go.
|Three 50 lb weights inserted|
|Gluing up centerboard|
|Putting Dynel cloth on centerboard|
|Looking aft - Cabin ready for Centerboard|
|Putting Dynel cloth on interior of Centerboard Trunk|
|Trunk half primed and painted|
|Slot in forward bulkhead and bottom for trunk|
|Scribing the Centerboard Trunk bottom to fit flush with bottom of hull|
|Centerboard Trunk installed|
The trunk was made longer on the bottom than needed, then scribed, taken out and and cut and then epoxied to the floor of the hull. This joint will be finished on the bottom when the boat is lifted to install the centerboard.
Cabin and Coach Roof
The cabin sides and coach roof beams took forever. Mostly because I didn't know what I was doing and thought this through and experimented many times before cutting the sides of the cabin where they meet the roof. Here is the beginning of this process.
|And again from the front, below|
In the photo above, you can see on the right, the 12:1 vertical scarf in the half inch plywood where the curved front portion will be attached. You can also see the fore mast partner where it joins the main deck beam.
The bulkheads toward the rear of the cabin were only four feet high, so I extended them higher using a sine wave cut rather than just a straight joint. You can see this in this photo of the cockpit and cabin with the coach roof beams in place. The hole for the companionway hatch entry is quite large. One reason is that the ceiling of the cabin is low, about five feet, so, when cooking or working in the galley, if you leave the sliding hatch open, you can stand up - and also have a nice view.
Notice the darker color the E Bond 106 gives the plywood interior. This photo is quite a bit further along, the coach roof beams, deck beams and centerboard trunk having been installed.
The deck beams were made mostly of ash and the compound cuts where they connect with the sheer clamps and trunk carlins could not have been done without my Japanese hand saw I purchased at Lowes.
|Sawing an ash deck beam|
|Bow deck stiffener with screws which will hold it|
|Mast partner and screws|
|Half beams for deck. Laminated coachroof beams on floor in background.|
|Laminations - after end of cockpit coaming|
|Same, but more finished|
In the photo above you can see the rear mast partner (no hole made for the mast yet the tiller post will also go through this) the deck beams, carlins for the rear hatch and the after deck stiffener.
Below is the coach roof with the interior ceiling of 3/16 inch plywood from Lowe's having been installed center to center on the beams and then 1 1/2 inch Dow board insulation epoxied between the beams and to the interior ceiling and being flush with the top of the laminated coachroof beams. I reinforced the joint where the cabin side meets the coachroof by putting a 1 1/2 wide piece of 1/2 inch plywood between each two beams and another strip of 1/2 plywood about two inches wide, tapered at the bottom, around the sides even with the top edge.
|Coach roof - ready for top lawyer of 1/4 inch ply|
|Close-up of roof with insulation in place|
Next will be the quarter inch plywood roof epoxied to complete this "sandwich" roof. Below is a detail of the centerboard lifting compression post. There will be a sheave at the top for lifting the centerboard.
|Compression post for lifting centerboard|
|Detail of mortise on top of post|
A brief interlude here as Mary Ann and I are moving from our home northeast of town into Charlottesville, so the boat has to have a new place to be completed. Below, she is being readied to be lowered on to Gil Roberts' equipment trailer.
|Carlos helping to ready the hull for trailering - hi tech|
Arrival at my brother, Piers' home in Somerset, where we grew up, and my mother, Nichiko, lived for thirty years. Below is a photo of the Sharpie Nichiko arriving at her new home where work can start again.