NZL149 - David's Refit Diary
Many thanks and welcome to new
Addict David Haylock of Upper Riccarton in
Christchurch. Proud new owner of NZL149. David is in the
process of returning Fishy Tales to her former glory and
will be sending through updates that will be posted here.
Anyone with any help or advice
to offer can email David by clicking
Thought I might try and send through a bit of a diary of the
work I do on KZ149 to get her back on the water in good
shape. I would like to send a detailed picture diary as
well, but instead of buying a digital camera I bought a
A-class cat......... Oops. So the photos will be from when i
borrow other peoples cameras and therefore may not show
things progress very well.
new to A-class and in fact new to cats in general, so when
John first delivered the boat to my place the first thing I
did was put the rig up and just have a look and get an idea
of what I was in for. Then once I measured my garage and
found the hulls would just fit, it was time to pull them
apart to make them a little easier to work on and get them
out of the weather.
off to bunnings for me and get a paint scrapper and the
cheapest heat gun you can get your hands on. Thanks to the
earthquake Uni has been closed and I've been a little
limited in what I can do, so as a result (and 8 or so hours)
the hulls are now virtually paint-less and ready for a good
sand, bog and fair.
appendages have also been sanded and heavily bogged, but I
think I'll leave the fairing of them for a while, especially
as I'm thinking some new boards would be a good idea.
a quick idea of my plans, strip everything back, strengthen
and stiffen where deemed necessary (a bit of carbon will be
used here), repaint, rename and refit where I can afford.
can a student afford all this you may ask. Answer, I can't,
but a graduate engineer can. So I'll do all the cheap work
photos, none yet of the stripped hulls, I'll get there.
The rig, what to do
with a 30ft rig
The old hulls aren't
in bad shape, bit of work to be done though
The ally struts, new
carbon ones perhaps, something for me to think about
and I swear the boat fits in there somewhere amongst
all my other crap
and the boards + bog
She's all stripped back
now. Have done a bit of sanding and a little fairing.
Going to replace the fibre glass along the bottom join
of the hulls as it was a bit old. Got a couple of holes
to fix as well. All very structurally sound though,
which is nice. Got some carbon on the way to reinforce
the deck and help stiffen that general area. Does anyone
know of other places to get 200gm2 carbon uni, other
than nuplex, high mod and NZ fibreglass? Nuplex is all
out and nobody else has what I'm looking for.
Anyway, cheers Brent
Harsant for the email. I'm looking at building my own
boards, in similar fashion as I build my surfboards, are
there any objections within the glass towards
asymmetrical vertical boards? The old ones look a bit
inefficient. Have a paint guy coming round tomorrow
morning to sort me out hopefully. Brent made a good
point that 1 pot is more flexible than two pot, so will
definitely keep that in mind.
Did a weigh in the other
day as well, hulls are around 20KG, don't think that's
to bad for an old wooden boat.
Have some pics, that's
the main reason for this update.
idea of the size for family and friends. She looks
from the side. Hulls are very fair already which is
to get scrapped off, all the fibre glass
fit. Just. I'm trying not to use the laser as a work
Making sure the tramp is in decent condition
think some birds lived in here at some point
That's some old glass, older than me in fact.
Condition inside is pretty good
It's been a while since my
last update on KZ 149. The other day we had a
devastating earthquake as I'm sure you all know and I
send my condolences to anyone who has been affected. It
was a very scary event and I'm very great-full that my
work building survived.
About the boat. We moved
house/garage in jan so things slowed down because of
that and I'm still slowly organising my garage so that I
can do some work on her.
She's heading into the
finishing stages though. I have all my carbon for the
reinforcements, all the paint (thanks to international
yacht paint, great deal from altex coatings). I've
replaced the fibreglass along the bottom seam of the
hulls and faired that off (placed 1 layer of 75mm 200gsm
plain weave tape). So that looks good. Been trying to
fair off all the big dips and hollows and such in the
hull, not sure how fair I will be able to get the hull
but I'll concentrate on the wetted areas and the upper
areas of the hull I wont do so much work on.
Over Christmas time I
sealed the hulls with thinned epoxy. I've gone pretty
light on this process as I didn't really buy enough to
do lots of coats and I'm guess that I wont need to much
as the boat doesn't spend all its time in the water. She
looked good after sealing.
Time frame to get launched
has been extended. Looking for next season, so a winters
worth of work.
Hope that's a decent
update, got a few other things on my mind at mo, but
felt like it had been a long time since my last update
so thought I should get onto it.
Here's a photo update of
what I've been up to in the last week or so. Its been
quite productive as you can see.
I'll give another good
update in a while.
Update time again. Things
have been going along pretty steadily lately. I've
started making a few of the bits that go on the boat
instead of just working on the hulls though. Its meant I
get to finish things instead of just slaving away on the
One of the hulls now has
all the carbon on and is getting ready for painting and
finishing, the other hull still needs some sanding
before the final carbon goes on. I set the hulls up with
all the gear sitting on them to get an idea of how the
boats going to look, I start to forget that I'm working
on a big boat when I just have a couple of hulls sitting
around. It always amazes me how big the boat actually
I made a new mast rotation
thing (there must be a proper name for these things, but
I don't know it) The old one was looking worse for wear,
it was stainless but had a piece of steel welded to it,
so wasn't in great shape. So I grabbed a piece of 10mm
balsa and shaped a new one then coated with the black
stuff. I think it'll be strong enough.
And looking at whatever it
is that hold the stays on the boat (I'm not doing well
with names here), they were looking a bit old and messy,
so I now have a nice new set of carbon ones. About 14
layers of carbon in the laminate with different angles
to transfer the stress round the holes.
I've also started the
process of making some foils. For this I'm using a robot
milling machine that my flatmate is working on at uni.
So we're trying to sort out the machining code at the
moment because we don't have a computer program to
convert a model into code, so the code is coming from
numbers on a excel sheet. The foil I'm using is a
NACA25008 (which is a 5 series foil) This is an
asymmetric foil that I'm hoping will help to lift a hull
out of the water earlier and decrease leeway when
sailing upwind. So for the mold I'm machining out a
couple of slabs of MDF to create a female mold.
I think that's about it
rotation thing out of the vacuum bag
Cleaning it up with craft knife an hacksaw. The old
one is in the background.
Finished, next to the old one. I've set the new one
up with control for over mast rotation as well for
straight down wind.
next to new
not only do they look cool, but they weigh about 10
grams, bout a sixth of the old ones.
Testing the machining for the foil molds.
Approximate foil shape in the background. Looks a
little distorted in this picture.
only that was it finished and ready to go.
final carbon on the starboard hull. Continuous
200gsm uni all the way down the keel of the boat.
All the carbon on the boat is 200gsm which is pretty
light, but its just there for a little added
stiffness and a bit of pimping.
Been meaning to send
through an update for a while now. The boat is
progressing well. Into the finishing stages.
A few quick points:
Now have a trailer,
building a box for it and will have to add rails for the
boat to sit on.
All the carbon reinforcing
on the boat is finished, I had to fully vacuum each hull
3 times, I'm pleased that's over.
New centre boards are
progressing slowly (no molds yet) each time we've tried
the robot hasn't quite done what we want, so its taking
a bit longer than I'd like.
First coats of paint are
on and now I'm going to bog up the last "blemishes" and
fair them out before moving to undercoat then topcoat.
Am testing the clear coat
for the carbon at the moment.
Have spliced loops for the
soft joins from the stays to the boat.
Drilled the holes for the
Assemble the boat, put the
rig on and sail up. That was fun.
So currently my life
consists of work, paint, sand repeat. The warmer weather
is really helping with the speed of things and I'm
definitely looking forward to having it out of my garage
and on the water.
for the trailer, made from some nice cheap ply.
First coat of paint.
International Yacht Primer.
Rudders getting finished
just fits in the garage together. But can't get it
out like this.
late once I got it all sorted. Had a big smile on my
been a really busy last few months since my last update.
So a quick run down before I get into the whole story.
At the last update I was at the primer coats and putting
the rig up to check everything/dream of sailing. Since
then I finished all the painting, moved house again
(third garage the boat had been in), had trailer issues,
fixed trailer issues for a warrant the day before I went
away with the boat, sailed the boat, broke boat, fixed
boat, sailed boat, broke boat, yet to fix boat.
painting. I think I left the final fairing a little
late. I had put two coats of primer on to try and take
out all the sander marks and such then applied epoxy
mixed with fairing compound. I did this because I
figured it would be easier to see the areas that needed
it after painting, which it was, but in sanding the
fairer back I took off a fair amount of paint. I ended
up putting 4 (I think) coats of primer on. These were
pretty light and after each two coats I would sand them
down to fair. I think what I should've done was use a
high build primer (that would've made it a lot quicker).
the priming I put on two consecutive coats of undercoat
and then sanded back to fair (you could see the odd spot
of the grey primer after sanding but no longer any
wood). I used a brush to tip off the paint after rolling
to try and get a fairer surface, and this worked quite
well at this stage, I also tried brushing one coat of
undercoat on the rudders and that worked terribly (
ended up with far too much paint on).
moved onto top coats after sanding with 220 grit I
think. I put one top coat on and sanded back, this was a
bad idea, top coats don't sand well, used a lot of
sander paper and took a lot of time. After this stuff up
I applied two consecutive coats of top coat to finish,
each coat was tipped with a fine brush.
all the paint was going on, I was trying to fair the
carbon into the hull and itself (this wasn't much fun
either). After sanding each of the undercoats and top
coats, I would apply coats of marine varnish. I first
applied 2 coats, then two coats, then a final after the
final top coat. Each time I would over lap the varnish
over the painted surface and the paint over the
varnished surface to get a good seal. The main problem I
ran into here was using a satin varnish. After 4 sanded
coats, there are areas where the carbon looks quite grey
(the low spots) and really black (the high spots). I
used the satin because I didn't want a really shiny
(blinding) finish. In fact I should've used gloss coats
for the 4 fairing coats and the satin for the final, but
oh well. By the end you couldn't tell the difference in
surface when you ran your hand from paint to carbon,
although I have left the edge from the final coat of
varnish on, so you feel a slight sharp edge now, but I
figured it's not worth trying to sand off as the carbon
itself isn't completely fair due to the weave and my
struggling to get consistent vacuum.
that's the hulls pretty much finished.
was working on finishing the hulls, I also got my molds
made for my new boards just in time before my mate left
UNI and no longer had access to the robot. I haven't
done anything with these molds as yet as ran out of
time, but they look pretty good, so maybe this coming
a couple of small trolleys by laying foam over the hull
at the widest point and sticking it there. Then laying
fibre glass over top of the foam. This worked really
well. Then mounted plywood bases to them and small
inflatable wheels off trademe to the bottom. And after
breaking my aluminium axles on my first outing (one of
the things I broke) they now have steel axles that I
hope don't rust too quickly.
chain plates were fun to finish making and did look
really good on the boat (note the did). They're shown in
previous posts made from solid carbon plate. I was
always a little worried about their strength, but
thought I had tested them enough (by putting the
mainsheet block to them and pulling as hard as I could).
I also sliced 4mm dyneema in a loop and feed them
through the whole because I figured a shackle would
break them pretty quick. One of the chain plates however
failed on my first sail. Luckily after sailing for an
hour and when I was standing in the water holding the
shroud, so the mast didn't quite come down, but it was a
very panicked time. Since then the old stainless ones
have been on. Which luckily smartness dumb luck I had
drilled the holes in the carbon ones by using the
stainless ones as a guide, so the stainless ones fitted
right into the screw holes used for the carbon ones.
trailer. I'm really happy with how this has turned out.
I load the boat on back wards and can do it by myself
pretty easily. The boat sits pretty high due to the
wheels being below the hulls, but this doesn't seem to
be a problem and the boat tows really well (and I
haven't hit anyone else with the mast sticking out while
going round corners, just the odd tree). The trailer
however did give me warrant issue with me needing to
replace a wheel bearing and fit forward facing lights at
the last minute right before new years, good times.
first and second sail, 1st and 2nd of Jan 2012.
first sail was amazing. Had 0 - 10 knots of breeze on
Akaroa harbour and really nice hot day. When I got to
the breeze I felt the boat power up really quickly, the
acceleration was amazing. Got out on the trap and was
just flying the hull above the water at times. Went
flying past everyone else out there, was beautiful. Then
headed back to the dock to pick up my partner for a
quick first sail for her and that's when shit hit the fan
with the chain plates and the broken axle on the trolley
that I discovered as I went to take the boat from the
water. So it was back home to Chch that night (not
planned) to fix the issues and back and ready to sail
the next day. Replace the chain plates, replaced the
axles, lowered the trap to the correct height and
replace the mast spanner with the old one because really
dumb moment, I forgot to release it before I lowered the
mast, so the carbon one I built cracked in half.
sail. The next day a southerly had gone through and was
still blowing about 25 in the middle of the harbour but
there was quite a nice region in close that was about 10
knots with the odd bigger gust coming through. So rigged
the boat up slowly, not wanting to rush and waited as
long as I could for the wind to die, it didn't.
Launched, everything fine. Got into a gust near the line
of breeze, tried to tack back, didn't know how to tack a
big cat in strong wind (didn't back it back properly)
and didn't want to gybe as the wind was already to
strong. So made the call to sail across the harbour to a
bay on the other side for shelter to tack. That was like
survival mode, didn't want to trap as I didn't want to
fall off, sat with my bum against the traveller and held
on. It was a pretty quick reach but the waves hammered
me and the boat a bit. About half way across I heard a
crack and though it was likely the centre board, but was
too busy to do anything about it. Sure enough, when I
made it to the other side, I pull up the board, but
there isn't one, sheared straight off under load (I
don't think I hit anything, boat didn't jerk or
anything). So I tacked and swapped the boards over so
the board was on the leeward side and sailed back across
the harbour. Take boat out of water, think that feels a
bit heavy. Open up the hull and find a bucket full of
water and later find the centreboard case was punctured
when the board broke.
that's about it. Will get the case fixed, have some
carbon/glass/carbon plate here that I will use to cover
the hole and fixe the cracks with epoxy glue. Going to
borrow some old paper tiger boards before I get round to
making my new ones. Will also repair my mast spanner and
will look into making new chain plates. But for now it's
time to relax then head to Waikawa to sail big boats for
Nuplex resin; International single pot paints (thanks to
Azko Nobel for the good price); carbon from FGI (nuplex),
NZ Fibreglass, and deano41 on trademe, whom I can't
think what company it is, also got all my vacuum
consumables from nuplex. All these companies have been
great to deal with and provide good pricing as far as I
like to thank my friends for the odd helping hand,
especially during the move and with some of the carbon
laying. And my partner Abby for being really supportive.
thanks to all the people who have contacted me with
advice and support, it's been helpful.
Phil from Lyttleton sails for doing a quick fix up on my
tramp so that I could sail, will get the beer to you
figure I've spent about $2000 on the boat ($2500 max).
The expenses that I didn't really count on was all the
consumables. They were a constant drain on my wallet,
especially masking tap (I used a lot doing the two tone
thing with the carbon and paint), sanding paper and
rollers for painting. Also the number of fasteners I
bought, I should've been more organised and got these
cheaper rather than going to burnsco and bunnings. Those
places have far too much of my money.
for the pictures:
cat in a cat, Panda loves crawling inside the hulls,
I figure she'd be good for trimming the hulls.
Robot doing its work on the foil molds
of the hulls reaching its final painting stages
rudders and centre boards. At this stage I decided
that I wouldn't have enough time to make new centre
boards, so I started work quickly on fixing the old
ones, maybe a reason why one broke and the other is
foam and fibreglass for the trolleys.
Bolted together, properly this time.
First time on the
trailer and testing everything.
First time fully
rigging the boat on the 29th of December and working
out everything that I need to buy and making sure
everything else works.
The boards were topped
with carbon and a loop of black rope and sat flush
with the deck so that nothing poked up, looked
really nice too.
sail on the 1st of Jan
And more sailing, you
really have to sit a long way forward to get the
bows in in light winds, should've left panda in the