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@buildingaspankerinnz
Most of the filler is sanded off again with a longboard, resulting in an approximate 7mm deck. It was very convenient that wheels were added when the strongback was converted into the cradle as we could wheel the boat outside for this job.
The deck needs also strengthening as 6mm marine ply is too thin. First all connections and screw holes were filled using epoxy-filler and after sanding a smooth surface was created to apply a layer of glass fiber cloth. The same procedure was followed as with the hull. The cloth was first put in place and soaked in clear epoxy making sure no air bubbles were left between deck and cloth. When that layer was still tacky an epoxy filler was added. We worked in two stages as the surface was too big to do the job in one go (epoxy would harden too much before the second layer could be added).
The first phase, now filling all screw holes with epoxy.
At the points where the sheets are joined with a scarf you can’t use too many screws when epoxying. A makeshift clamp was rigged and several weights were used to add enough pressure to keep the connections in position for the epoxy to harden.
Before starting work on the deck three more layers varnish were applied to those areas hard to reach when the deck is in place. The deck consists of 5 separate 6mm plywood panels. One for the aft deck, two for the gangways and two for the bow. Each sheet was scarfed to create a strong connection with the next section. The bottom of each sheet is treated with Everdure from International followed by three layers of varnish.
Next the support for the main sheet track was installed consisting of a mahogany beam. The beam is bolted through the hull and embedded on each side of the inside of the hull by three mahogany lattices (U-shaped) layered on top of each other to give enough support. A fourth mahogany block is put on top of the beam, so it can’t move in any direction.
As per tradition we placed a coin under the mast heel in order to receive fair winds when sailing. We ordered the mast in Holland as it turned out to be more cost effective (including shipping) than get a custom made one in NZ.
The centreboard is finished as well: 8mm stainless steel (316) and best of all... when testing, it fitted nicely in the centreboard case.
Before the deck construction was started, the floorboards were made without the support battens, as the leftover sapele of the deck construction is used for that. After completing the deck construction the floorboards can now be completed as well.
In the mean time the bow section is strengthened with doublings to accommodate deck gear.
The mast heel base is extended to accommodate any future mast heel.
An extra beam is added on the outside of the hull for more grip when standing in the trapeze.
To round the cockpit corners, multiple layers of plywood were used in the centre and finished with an epoxy layer to create the final curve (using a 4mm plywood mould not shown in the picture).
Next phase is adding the deck construction, for this Sapele beam clamps are used.
From top to bottom: stern, foredeck and side deck. Note the two beams added for support while working on the deck construction. Also note the plywood, as part of the deck construction, where the chainplate is positioned.
Now is also the moment to add the base of the two chain plates using countersunk bolts and epoxy.
Two self-bailers, one on each side of the centreboard casing, are added. These bailers will drain the water out of the boat while under sail when activated.
In the stern two drain holes are drilled for draining water when it’s on the trailer.
A U-bolt through the stem is put in place, to help lifting and launching the boat on/off the trailer.
The next step is preserving the inside of the boat by applying two layers of Everdure, an impregnating liquid epoxy, followed with a layer of clear epoxy. Later on it will also be varnished for UV protection.
The boat is temporarily parked on a couple of benches while the strongback is recycled into a mobile cradle. Now the boat can be moved in and out of the garage when needed.