Revenger build thread!! - Page 12

larby · 12-03-2010, 09:23 PM

Wednesday was spent applying the 'complex' to one side of the hull. This consisted of a layer of 2oz mat, a layer of thick woven (not sure of weight), then another 2oz mat, all laid together so it bonds as a sandwich. All joints were staggered so no two layers joined in the same place. An overlap of 8" each side of the keel was added for strength.

I like to think I did a pretty good job of it. It's not hard, just fiddly at times and very frustrating trying to get used to the cure times. Still, I took my time and managed to end up with a pretty good job!

Thursday was a repeat of wednesday on the other side, god was I glad to get this done, it was so hard trying to reach everything, especially up front!

larby · 12-03-2010, 09:34 PM

So, now the whole hull had a complex over all of what was left from the strip down. This runs all the way up to the rub strip. The difference in the strength of the hull is phenominal, I can now wander about in it without it looking and sounding like I'm gonna fall through!

I decided I wanted more strength under the stringers, this was a previous weak point of the boat. I laid another 8" wide complex over each of the strakes where the stringers will sit. These pretty much join in the middle between the inner and outer stringers, so 1/3 of the hull is now 2 complexes thick, the same as a 100ft Aquastar! All of the edges were well feathered out to avoid there being any hard spots.

Next up was to measure for the stringers. I'll let the photos do the explaining here. Main issue was that the top of the stringer is slightly curved as well as the bottom. To allow for this, i measured the gap in the middle with the beam held straight, then weighed it down to the chine and measured again so i could replicate this same bend on the sheet.
I then measured down in 1ft spacings all along the length of the stringer to give me the sizes and wrote them on the top. Simples!
Probably looks gash as hell, but worked beautifully!

larby · 12-03-2010, 09:47 PM

Well I must have changed my mind a hundred times about what I was gonna use for stringers. I recieved tonnes of advice about what material is best, all of which is greatly appreciated. I can only go with one method though, and I chose ply.
I don't believe there's any wrong or right materials to use, each have their own merits, but some were too expensive (douglas fir), foam was only available in the wrong size, and the way I see it, ply has been used in many many boats for donkey's years without major issues, is cheapish, simple to get and simple to work with.
I hope people who advised against it won't hold it against me!

Anyhoo, moving swiftly on...
I found both stringers were (thankfully) identical. I removed the frame from the boat and set about pinning the beam to the sheets of ply with the same curve applied. I then simply measured down according to the measurements, then had a game of join the dots! The stringer is 15ft long, so 2 sheets of ply. Obviously I'll stagger the joints and bond the layers together with a sheet of mat inbetween too.

Once I'd cut one stringer out, I could then use this to mark out for all the other layers for both sides. (held together temporarily with 2 bits of 2x1!)

That's all for now. Tomorrow I'll be bonding the stringers together and hopefully glassing them in. Want to stick to 24hrs tops between layers to ensure I get the best possible chemical adhesion.

Originally I thought I'd be done with stringers and bulkheads in within 3 days, so it's taken a touch longer than anticipated, but I'm really happy with the progress. She's coming along well and is starting to get strong again. Can't wait to get the floors and bulkheads in, then she'll really be a proper boat again rather than a bare hull.

All the best,

James

Big V · 14-03-2010, 07:16 PM

Quote:

Originally Posted by larby

Hi Glen,

Hope to see you out there some time this season!

James

and someone is going to get smoked!!!

larby · 28-03-2010, 08:24 PM

Well it's been a while since I've updated this! Had a week from hell with work, then went ill for a week with Norovirus!

Still, there's been plenty of progress... from the top...

Got the stringers finished off.

First pic is to show the extra complex of glass over where the stringers sit. The old stringers had started to crack the strakes for a multitude of reasons, that's not gonna happen again.

Second pic is all the parts cut out and ready for mocking together for test fit.

Third pic is an example of some of the complexities. The strake these sit in end 1m from the transom.The old stringers just had a big step in, I shaped these so they followed the shape of the hull perfectly.

I then mocked them together and routed & sanded every edge to have a 3/4" radius. On the top this helps the glass sit, on the bottom it stops any edges causing issues!

larby · 28-03-2010, 08:28 PM

I hadn't made a full template for these, just relied on the accuracy of my measurements! Thankfully a test fit showed they were just right, no adjustments needed!

They were then glassed together to make one beam from the parts. I didn't take a pic as there's nothing at all to see! The finished beams were immensely strong.

larby · 28-03-2010, 08:34 PM

Once the beams were completed I bedded them into the hull, ensuring there were no voids underneath like before, and a nice 1" radius where they meet the hull to aid glassing. This was trickier to keep neat than I expected, ended up doing a bit of sanding afterwards!

Again, I didn't get any pics of me glassing them in. (you can see it easily in the next stage). They were glassed over with a complex extending 9" from each side. Man was it a tricky job getting all the bubbles out here, really stressed me out!

larby · 28-03-2010, 08:46 PM

Caught up with myself now!

Yesterday I was so happy to be able to get on with the floors and bulkheads. My plan is to make up all the parts, then glass them all to seal them, then fit them all together, rather than doing it a section at a time.

Started with the front 'stub' bulkhead. I can't get the cuddy floor in with a full bulkhead in place, but I've got to glass in the fwd bottom of the bulkhead before I put the floor in. Only solution was to make this bulkhead in two halves.

Pics 1 & 2 are this front lower bulkhead, the first I've ever made. I was pretty chuffed with the result! I'll do all the sanding and finishing of the edges just before I glass them just in case i need to adjust anything.

Next up was the template for the cuddy floor, shown in pic 3 & 4.

Pic 5 & 6 show the floor in place. It's got a 12" x 7" access hatch by the bulkhead and again 120cm up. I've got 2 avon flotation bags. I intend to stuff these under the floor and then inflate them, the area under there is just the right size. That way they don't need to be knocking about in the cabin, I'd like to keep it really nice in there.

larby · 28-03-2010, 08:52 PM

Did some measuring and realised I needed to take a chunk out of the top of this lower bulkhead for the entrance to the cabin so I removed it and added the cut. This is why I'm mock fitting everything together before I glass it all up and fit it. Much easier to make adjustments at this stage!

I then measured out and cut the side floors for the cockpit. Can't wait to get these made, it really turns it into a boat again! Had some visitors at this point and had to go get my mum from the airport so I never got the passenger side cut out!
Managed to test fit and take a quick pic of the driver's side, that's all for now!

Quite pleased with my progress but I need to really hammer it this week to catch up on the last week or so I've missed!

Spax · 28-03-2010, 08:53 PM

Top work! when are u hoping to be done by? looks like the hull will be 100% better then before, looking forward to the launch!

larby · 28-03-2010, 08:57 PM

Hoping, rather optimistically, to be ready by the beginning of June. That's the date of our second race and my birthday so it'd be nice. Doubt I'll make it though, but hoping to be in some time this season!
At the end of the day though, I'm more concerned about doing it right than in a specific time, it'll take as long as it takes, i'm already pushing myself and family way more than I should!

I can't wait for the launch either, it'll be nice to have a good working boat again after the last couple of years!

James

peterunwin · 28-03-2010, 09:19 PM

Quote:

Originally Posted by larby

Caught up with myself now!

Yesterday I was so happy to be able to get on with the floors and bulkheads. My plan is to make up all the parts, then glass them all to seal them, then fit them all together, rather than doing it a section at a time.

Started with the front 'stub' bulkhead. I can't get the cuddy floor in with a full bulkhead in place, but I've got to glass in the fwd bottom of the bulkhead before I put the floor in. Only solution was to make this bulkhead in two halves.

Pics 1 & 2 are this front lower bulkhead, the first I've ever made. I was pretty chuffed with the result! I'll do all the sanding and finishing of the edges just before I glass them just in case i need to adjust anything.

Next up was the template for the cuddy floor, shown in pic 3 & 4.

Pic 5 & 6 show the floor in place. It's got a 12" x 7" access hatch by the bulkhead and again 120cm up. I've got 2 avon flotation bags. I intend to stuff these under the floor and then inflate them, the area under there is just the right size. That way they don't need to be knocking about in the cabin, I'd like to keep it really nice in there.

Hi James,
You are making some really great progress, you must be putting an awful lot of hours in? it is good to see you are on to the nice work now

Don't be in too much of a rush to finish her sometimes when there are numerous options for a particular job i find it helps to go & do something completely different for a day or so & when you come back the picture is much clearer

All The Best

Peter & Carolyn

Jon Holmes · 28-03-2010, 10:31 PM

She is coming along nicely.

larby · 29-03-2010, 12:55 PM

Cheers Jon

Peter - Yeah, I'm usually doing 2 nights a week, plus all day saturday, but I work very hard when I'm up there! It is indeed great to be onto this part of the build!
Work normally manages to clear my mind when I can't decide on something, nothing too tricky to think through at this stage though!

James

larby · 02-04-2010, 09:11 PM

Got the rest of the front and the rear bulkhead cut out the other night, really starting to feel like a boat again now!

larby · 02-04-2010, 09:18 PM

I just couldn't stand the mess of the engine bay 'surround' above the bulkhead, so out came my old friend the sabre saw!
Plan was to remake this front piece to keep the cabin the same size, but gain about 8" room in the engine bay. This will give me room to stroll the whole way around the engine

larby · 02-04-2010, 09:25 PM

Today's work was making the replacement part to fit where I cut out. Took me a whole day to build, wanted to get it perfect.
I was gonna continue the water channel around the front but it would've been really hard to achieve this with the way I was doing it for no real gain in the long run.
Anyhoo, here's a couple of pics from the making process... It mounts via a panel behind the side i forgot to take a pic of, you can see the shape/size from the pattern of screws holding it in place. I'll get a pic when it's out for glassing tomorrow.

larby · 02-04-2010, 09:35 PM

So here it is with the bulkhead in place too. I've moved the actual bulkhead forward 5" as there used to be a useless gap behind the seats.
Over all, I've gained a massive amount of space in the engine bay, and it looks a whole lot better to boot!
Most likely gonna do the engine hatch tomorrow, and/or start glassing up the current woodwork ready for fitting.

Thats all for now,

James

PerformanceDodge · 05-04-2010, 12:41 AM

Hi James, boat looks like it's coming on really great can't wait to see it finished.

Pardon me for asking but are you not going to have a centre strake or inner keel running down the centre of the boat. Would have though it would be the most important one as the keel probably takes the most stress. If you hit a floating log or plank the keel takes a massive impact. Most trailers have a centre keel support and if you beech it again all the load is on the keel.

But there again I know nothing about boat design so I am properly being a nober.

Regards David

larby · 05-04-2010, 10:17 AM

Hi David,

When I bought her she did have a centre longit of sorts, a single 1/2" strip of ply that was almost glassed over. I don't believe it did anything!

I was going to replace it until I spoke to various people 'in the know'. Apparently it's not usual for something like this to have that centre longit, the strength is in the glass here.

So to cut a long story short, ther was already a fair bit of meat left in the centre as this bit hadn't delaminated.
When glassing, I did a side at a time, with a 6-8" overlap in the middle. As a result there were 2 complexes (2oz mat, thick woven, 2oz mat all laid as one) over the centre 12-16" of the keel. I then added a further complex when strengthening here, and under the longits.
So the keel has 3 complexes, plus what was already there, and the longits (stringers) have 2 plus what was there, plus another complex that goes over the stringer. It's solid as a rock.
To put this into context, the hull of a 150ft aquastar superyacht is 2 complexes.

Hope that answers the question for you, anything else just fire away!

Cheers, James