To explain the method a bit - I
have hull moulds split on centreline for the port & starboard
sides of the hull. The moulds have been machined from a block of
high-density polystyrene foam, on a backing of 3mm MDF to form
the sharp edge on centreline.
Because the polystyrene foam is
much too soft to be able to vacuum bag a hull on (the vacuum
will just crush the polystyrene), the foam is covered with
a light (~0.7mm) fibreglass laminate to form the actual mould
surface and the vacuum boundary.
More
mould assembly
(click on images to enlarge)
Have been continuing to work on
my hull moulds - and now finally the starboard mould is
finished. Unfortunately it looks like there may be a delay in
sourcing the carbon fabric for the skin, so I will use up some
time by preparing the port side mould as well.
The photos show the mould skin
being laminated, and the final coat of Duratec being painted on
the surface to give it a good hard wearing finish.
Still lots of work to do - but
it's good to finish one part, soon I hope to do some work on the
actual boat rather than mould building...
And out
pops a boat
(click on images to enlarge)
Laminating inside skin on inner shells 1
Laminating inside skin on inner shells 2
Laminating inside skin on inner shells 3
Laminating inside skin on inner shells 4
Fairing core on inner shells
Laminating outside skin on inner shells
The four hull shells are each
moulded (inside skin, core and outside skin for each) - the
laminate is a 200gsm carbon cloth @ 45º each side of 6mm Airex
foam core, with some additional reinforcing to stiffen the hulls
in fore & aft bending. Getting the core to fit nicely was a bit
of a chore, with hindsight I should have built female moulds to
make core fitting easier and reduce the amount of fairing work
needed later. Oh well, you live and learn...
Once the hull shells were all
made I took the chance to mock up the platform approximately as
it will be - just so I could dream for a while about it being
finished!
Then the bulkheads, chain
plates and centreboard cases were made & bonded in, and the hull
shells joined. It was good to finally see the real hull shape
after all that time.
Next will be some filling &
fairing work before bonding the beams on, then it will really
fill up the garage! At this point each hull weighs 14kg - will
increase a little with painting but I'm pretty happy with that
so far.
So I'm hoping to be doing some
sailing this summer - looking forward to seeing everyone at the
Nationals in Napier!
All the best, Daryl
(click on images to enlarge)
First platform setup
Installing bulkheads
Installing centrecases
Shells ready for joining
Ready
to laminate hull join
Getting
very close
(click on images to enlarge)
Assembly Jig
Fairing Hulls
Joining Beams 02
Joining Beams 03
Joining Beams 04
Here's another update. The hull bottoms and sides had to be
faired after joining the halves, and now after building the jig to
hold everything flat, straight & parallel Dad & I have laminated the
beams into the hulls - hooray it looks like an A-cat finally!!
Won't
float yet as I haven't put the transoms on, but progress is
definitely being made. Next will be some work on tramp tracks,
traveller, mast step, c/boards, rudders, stocks, tillers, mast,
boom, fittings, painting - the list goes on!
All
the best, Daryl
Close
but no cigar nationals
(click on images to enlarge)
Turning over
Off
for the tramp fitting
Ready for painting 01
Ready for painting 02
Off to the painters
Wet
n' drying hulls
Just a quick update on progress over the last couple of months.
After much fairing & sanding the platform had it's first road trip
off to get the tramp fitted, and then following more sanding it had
it's primer coat of paint rolled on before again going off on a road
trip to the painters to spray the top coat. Now it's ready for
fittings to go on and all the little details!
Unfortunately
I've run out of time to get down to Napier for the Nationals -
disappointing but, of course, every thing takes longer than I think!
All the best for the racing, hope everyone has fun and see you in
the new year.
Cheers,
Daryl
It
floats!
(click on images to enlarge)
Centreboard bearings
Rigging 1
Rigging 2
Rigging 3
First sail 1
First sail 2
First sail 3
First sail 4
First sail 5
Finally I can send some photos of a working boat rather than an
object in a garage! First sail was On Mon 25th Jan at Hobby, in
winds varying from 5kn at the ramp to 18kn in the channel -
definitely a bit scary for first time out!
The boat has come together really well and feels great to sail - but
then again so do all A-cats! It's good to start sailing and getting
the boat sorted, really looking forward to some racing with the
Hobby crowd over the next few weeks.
Hope to see you soon, cheers Daryl
PS - it will be NZL 246, named Scythe (will do some stickers and
change the sail numbers when time allows, but sailing is first
priority now!)
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