Sunday, April 17, 2011

Glassing the exterior of the starboard float (finally)

I know its been awhile since the last update (1 month and a day), sorry for the lack of updates.  Progress has been somewhat slow, and pictures of fairing is just not that interesting.  In all, I think I applied putty and sanded the entire hull a total of five times ... five miserable, shoulder burning, lungs gasping, just shoot me already, times!  Keep in mind that the number of iterations was not because the hull wasn't already fair, but rather to address all the fine details now while it is relatively easy rather than waiting until the glass is on.  In any case, the hull is very fair, so it is time to move on to the next step ... glassing the exterior.
Being the exterior, and considering all the effort that went into making the hull fair, we wanted to ensure the exterior laminate had minimal seams to sand.  So we decided to lay on the glass in a single sheet rather than overlapping 50" sections.  This wastes a little more glass (5 feet to be exact), but it eliminates five overlapping seams.  Of course, laminating a single glass layer that is 24 feet long is a little tricky (at least for novices such as ourselves).  I couldn't come up with a way to wet the surface in sections before rolling out the glass that I was confident would work.  So we ended up laying out the glass dry and then rolling on the epoxy.  Here you can see the glass fabric covering the hull awaiting a slimy, sticky epoxy glaze.

Here is Dawna working away at saturating the glass.  It is important that the glass be fully saturated to ensure the epoxy bonds the glass to the foam.  We also squeegeed the glass periodically as we progressed to force out any trapped air bubbles.  It sounds like miniature kernels of popcorn popping  as the tiny bubbles are forced out.
 And here I am doing some final touch up work on the extra reinforcing strip.  It took about three hours to epoxy the entire half with both of us going continuously.  I mixed all of the epoxy and Dawna did most of the application.  It is a good idea to have one person focus on mixing epoxy so the batches are consistent.  We smoked one batch (literally, smoke rising and plastic liner distorted by the heat) when I dumped a new batch into a partial batch that had been sitting for too long.  After that, we made sure we always finished a batch before making more.
And here is the view at the end of the day.  The laminate came out very clean and uniform.  You might notice the extra fabric on the bow.  This is peel-ply that I applied to hold the edges against the foam tightly until it cured.  We could have applied peel-ply to the entire hull, which could save a lot of final fairing effort if done right.  I felt that we were already moving pretty fast just keeping up with the epoxy we were applying to the glass.  Trying to add the peel-ply on top without screwing it up seemed like too much of a risk.  Plus I expect I would need to do some final sanding even with the peel-ply, so maybe more effort than it is worth.

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