Parts cut for mounting modules

 In addition to the progress on the port float, we are preparing to fabricate the first parts of the main hull. If you recall I was vacuum laminating various panels a couple weeks ago for the "central mounting modules" (patented by Ian Farrier).  These modules provide the load bearing structure supporting the beams on the main hull.  There are some big loads on these components when the wind is trying to heel the boat over and the leeward float resists by push into the water.  Ian includes lots of warnings with skulls and crossbones to make the point that these modules must be built carefully and to his design.  I spent the past few days carefully laying out the components and cutting them to size (note the tools in the photo were mostly supporting actors, the table saw and band saw played the lead roles).  Many of the cuts are at odd angles, so I had to carefully think about how I was going to make the cuts to ensure accuracy.  Here you can see most of the parts just about ready for assembly.

The highest load components are cut from 4.5 mm-thick solid glass reinforced laminated sheet.  This was one of the panels I made on the vacuum table.  Ian's instructions estimate the solid sheet will require about 9 layers of 12-oz bi-directional glass.  In actuality, mine required 12 layers, with alternating layers of bi-directional (0-90 deg fibers) and double-bias (45-45 deg fibers) fabric.  I am not sure if the extra layers were needed due to the vacuum press, or due to the fibers being more uniformly spread out in my double-bias glass, and hence thinner than the bi-directional glass.  In any case, the panels is solid and heavy.  Feeling the weight of the solid panel compared to a foam-cored panel really shows the difference in weight of a solid laminate boat compared to a cored laminate boat.

In addition to the numerous small parts, there were also four large sections that form the backbone of the modules.  These sections are about six feet long, and will eventually span the main hull.  Next time I'll show you the high-load bearing pads I am currently fabricating out of lovely white oak (very old-school, indeed!)