Finished Cockpit Glassing

So 25 yds. of new fiberglass arrived on Tues.  Since everything was prepared I rolled out a length for the center of the cockpit including the foot well.  This was by far the most challenging fiberglassing I've done to date.

The geometry of the footwell in combination with the front of the cockpit and the transom makes for some interesting curves and bends.  I cut darts and overlaps where I thought it made sense and smoothed everything out.  Again, trying to get everything as close and as smooth as possible before mixing a drop of epoxy.

I started laying down the resin with the center of the footwell and worked my way out and up the sides.  I had to do this while sitting in the cockpit and trying to avoid disturbing the dry glass that was there.  This involved some pretty strange contortions where at times I was on one knee with a leg hanging out of the boat while leaning over the footwell.  I had a difficult time with getting out all the bubbles in the corners and to a lesser extend the bottom edges of the footwell.

From there I moved on to the forward center section of the cockpit right behind the companion way opening.  This being flat was much easer to do.

The rest of the area to be epoxied could be reached from outside the boat and also flat so it was much easier to do.

Upon inspecting the work I noticed that I still had some moderately sized bubbles and lifting in the corners and along the edges of the bottom of the footwell.  I went back and worked out as many of these as I could.

After about 2 hours (using slow hardener) I went back to check the work and some of the bubbles had returned (or I just missed them in the first place).  I put on a latex glove dipped my finger in alcohol and pushed these back down.  That did the trick for most of them.

After drying I noticed a few small bubbles that I will have to take care of and there will be some sanding in the corners to remove a few rough strands of glass.  But it is a step done.  From here out the glassing should be MUCH easier.

 Hours this session: 4

Hours total: 443

Glassing the Cockpit

After getting the cabin top glued down I went to work rounding everything off.  I did most of this work with a sanding block and 60 grit sandpaper.  It was pretty easy work.  I also did some filling of cracks, divots and holes that I incurred during the process of building.

I rolled out the last of the fiberglass that came in the kit.  I knew I was going to run out of this because I chose to fiberglass a lot of areas that aren't called for in the manual.  These included the bottoms of the seats and the bottoms of the foredeck and cabin top.  I ordered more from CLC.

I laid out the glass and cut darts to fit the corners.  Using a large "wallpaper brush"  I brushed and stretched the fabric.  Instead of using my normal roller and squeegee method I saturated the cloth using a cut-down chip brush to keep the fabric stretched out as much as possible while I was wetting it out.

For this round of fiberglassing I chose to use a technique that was outlined in a video I found at OffcenterHarbor.  This is a for-pay web site that has a lot of information about small wooden boats.  The video was one that shows how to fiberglass a stitch and glue kayak.  But the techniques that were demonstrated seemed like a method would also work for me.

In the end the technique worked nicely and I felt very much more in control of the wet-out process.  As I got better with it the technique the results improved the starboard side was done first.  The port side used noticeably less resin and I had less pooling as I learned the technique.  The final results on both sides were very good.  I actually look forward to do the cabin top and the bottom of the boat with the same technique.

The footwell and set centers will be done next.  I'm waiting for more fiberglass to arrive so that I can continue.

Hours this session: 10

Hours total: 439

Cabin Painting and Deck Install

Painted the insides of the cabin in preparation for installing the cabin decking. I used a scheme that was inspired by Jeff Hatch's build. Turned out very nice.





With some help from my beautiful wife I was able to drop the cabin roof directly on the correct spot. I had to hurry to get all the screws in and tightened down before the epoxy set up. Had to rush to get the internal squeeze out cleaned up. In the end I got the job done and had another success.




After the screws were removed I removed the overhang with a router and a cutoff bit and then used a grinder to sand the edges flush. I also removed the companion way spacer from the companion way bulkhead. Now it's MUCH easier to get in and out of the cabin. Feels good to get that last large piece of plywood in place.

Hours Total: 435

Location:Jackson Woods Ct,Meadow Woods,United States

Getting ready for the cabin top

After doing some trimming, clamping, swearing, adjusting, swearing and clamping I finally got the transom skirt in the proper place and epoxied down.  Didn't make too much of a mess of it.  Nothing that can't be scraped or sanded off. 

After a little sanding it looks good.  I made the bottom lamination from cypress and then used white oak for the top.

The ends really look nice feathered into the seat back tops.

Its amazing how very strong and solid that it makes the transom and consequently the whole boat.  The plans call for a oarlock for a yuloh.  I was afraid that it wouldn't be strong enough to support the pressure of using a device like that on the top of the transom skirt.  I'm not worried anymore.  I'm sure that the construction will easily stand up to that kind of use.

The plan is to leave most of bulhead #2 bright with white trim edging that will be trimmed with marine vinyl tape.  In addition I wan to leave the edges of the dorade vents and windows unpainted so that I can glue trim rings on later.  There will be about a 1" white border around the bulkhead openings.

Like many others I'm creating a bright (unpainted) area on the back of the companion way bulkhead.  Again the rest will be edged in white with a vinyl border.  The above will be primed and then painted.

Hours total: 420

Seat Back Tops and Electrical Panel

Filled the seat backs with expanding foam ala Jeff Hatch's pocket ship.  Great idea and works nicely.  The amount that Jeff recommends to purchase seems dead on.  Glad he did the math and I didn't have to!

After the foam was trimmed off and the tops were glued on I used a cut-off bit in my router to remove the excess top.  This worked nice but still needed cleaning up to bring it flush with the seat back and the hull.

I built the electrical box and marked its location on bulkhead #2.  With trembling hands and sweaty palms I used my jig saw to make the cut out.  Turned out dead on.  As did the dorade vent openings that I cut with a 4-1/2" hole saw.  Note the hole on the right side of the electrical box.  This will be where both the battery and circuit wires will enter/exit.

This is the electrical panel.  The cut outs are for a rotary main circuit switch and a 4 circuit switched fuse box.  It mirrors the lower cutout and will be hinged at its bottom and painted white.  Hopefully this will give bulkhead #2 a little bit of symmetry.

Her is the bottom layer of the transom skirt edging bent into place.  It takes a lot of clamps to hold it perfectly in place.  Right now it's not glued in position.  I sprayed this down with water after it was in position so that it will (hopefully) retain some of the curvature and be easier to reapply when it is dry.

Hours total: 410

A Milestone (sorta)

It's strange how you count milestones when working on a long project like the Pocketship.  It seems that events I thought would be memorable moments dissolve quickly into the shadowy past.  Accomplishments like completing the keel, then the lower hull, the upper hull the decking and the list goes on, seemed like moments to rejoice.  In reality they become a minor footnote and a transition to the next perceived milestone.

After several iterations of this I decided my milestones would be based on consumption.  Every time I used up the last of a material, I made a mental note.  I seem to get more pleasure from watching my stockpile of parts dissolve into a boat then I do for any particular accomplishment on the boat.  Don't get me wrong, I'm really proud of what I've done so far.  But for some reason it's easier for me to measure my accomplishment on how much of the supplies have been exhausted.

With that in mind today, while sealing the cabin top with epoxy I used the last of my first 5 gal. container of resin.  That's a LOT of resin.  I'm far past the 1/2 way mark so I'm sure I won't completely exhaust the last 5 gals.  It was kind of a neat thrill throwing away the old plastic jug and replacing it with a new one.  Seems like a silly thing to get a thrill from!

Since the last entry I spent time painting the inside of the storage bins in the seat backs.  They look pretty good if I do say so myself.  Once that was done I was clear to install the seat backs.

These went in very easy.  The upper sides were clamped and the lower were held in place with stainless steel brads.  Except for the area around the storage bin.  No brads there just pressure from some heavy weights.

I also spend a considerable amount of time planing the carlins for the dorade boxes and the cabin roof.  I tried to use a power planer for this and almost had a catastrophe.  Too many curves to work so I just did it by hand using planes and a spokeshave.

While the seat backs are drying I sealed the underside of the cabin.  I was going to get my artist daughter to paint some sort of cool design there before I installed it but it looks like her college schedule is going to be too busy.  I'll probably just leave it bright.

Hours total: 401

Dorade Vents

Weather here in FL is marginally cooler.  Now I can work in the garage without looking like I took a shower after 30 minutes.

The donate vents are up next.  Pretty easy although there was quite a bit of fiddling with the angle.

I also took the opportunity to add the carlins at the #2 bulkhead.  These were milled from white oak and  look quite nice.

Support was also added to the inside of the dorade vents.

 Carlins were added to the companion way bulkhead.  All of this construction will support the deck.

Hours total: 385