Thursday, August 29, 2013

August 2013

Not much happened in July this year...  Hot and rainy to do outside work.

August was much the same weather... though we spent the time working on getting the boat ready to move under her own power again.  We pulled in more Douglas fir for the engine room, and did an inventory of parts, pieces and general hardware that will be required. 

We built mounts for the navigation lights, and fiberglassed them into place.  They got the Snow White Awlgrip treatment with the intention that they can be taped off and non-skid painted around them when we spray the rest of the boat.

While we were spraying top coat, the inside of the front window frames were taped and sprayed. 

We've been in the midst of cleaning and organizing, making room in the "work shop" to put the steering helm and console back in place.  The lower pictures are some mock ups of the final design idea, where a center console holds the steering gear and allows the captain to step forward up to the window to see over the rails around the boat when docking, and have easier access to the front opening window.  Our friendly local glass shop is in the process of relocating, so the opening window is still opened with blue painters tape. 

Wednesday, July 3, 2013

June 2013

June...  Was the 19th wettest month in North Carolina's recorded history, which made it somewhat difficult to continue priming and painting the outside of Noel.

Nevertheless we continued on, pulling fillets and sanding.  The early part of the month was spent long board sanding, and finishing up fillets.  We sprayed two coats of sprayable fairing compound long board sanding in between each, a higher grit each time. 

When the time came for the Awlquick priming, we taped up the underside of the roof overhang and rear posts and did the whole job in one shot.  This is always exciting for everyone "close to the boat" as you feel like the most has happened in one day, and all the work done in preparation is shown.  While the primer is wet, you can see a wet reflection just like how it will lay when top coated and makes all the sanding worth while.

We are now starting on the center section of the stern deck roof, and will be wiring it for a stern navigation light, speakers, and recessed lights... and then a plywood skin put over it, primed and painted.  We aim to keep this area removable for future maintenance of davits and hardware for dinghy and jet ski mounts, hence saving it for last.  We are using 5 foot by 10 foot plywood, so the only seams over the 9 foot 6 overhang will be running along the length of the boat.

Our fiberboard window mold warped, from the high humidity of being an extraordinary wet month... so we await a replacement, and the promise of windows in the sides of her cabin.

All for now,


Friday, June 7, 2013

May...  Was a tough month to work outside, with showers that were deferred from April.

We faired the starboard cabin wall, to give a fair line at the inside fillet of the new roof overhang and ready the wall for windows.

On rainy days we were in the engine room, continuing to build floor frames and readying the engines to move forward.  

This has involved battens, long sticks that bend into smooth curves without lumps and bumps.  One prized batten made of fir and one 18 foot aluminum 1x1 box tube.  We use straight edges to determine that the surface is in the same plane top to bottom, and once we have true reference points top to bottom the battens are held against the curve of the cabin, at those intervals. 

Once we had a consistent surface, we mark and sand down the high spots.  Then we mark and fill the low spots with Awlgrip Awlfair. 

Once the batten lays in nicely, we then sprayed 4 gallons of Awlgrips Sprayable fairing compound over the wall and longboarded the surface true with long boards.  These boards make a crossing pattern, held horizontal but pushed at 45 degree angles from the top of the panel to the bottom. 

Once we had a smooth surface top to bottom, we boosted the radius below the framed window openings to full meet the batten with another dab of Awlfair fairing compound.   

Once we were happy with the wall, the top and bottom fillets were pulled in place, and sanded. 

The wall is now awaiting the forward doorway to be cut, and another coat of Sprayable Fairing Compound that will make the surface all one product, so the hardness of the underlying substrate does not impact the surface finish.  Sanding something soft, beside something yard yeilds a "Holiday" or halo shaped low spot that bends light in the reflection on the finished surface. 

After tropical storm Andrea makes her way through, perhaps we will get a good day with low wind to spray the next coat... and get some new pictures!


Monday, April 22, 2013

Finish work...

The cabin house windows are installed! (With the exception of the center opening window... )

We finished epoxying the 3/8ths marine plywood skin around the roof overhang.  The 15 panels were epoxy coated, primed with Awlgrip Awlquick and sanded out to 220 grit prior to being mounted, to save overhead sanding.    We will spend the next few days pulling fillets in the inside and outside corners and touching up where the seams go together.  The seams are backed with 1/2 inch marine plywood butt blocks to keep them both fair and strong. 

The temporary 2x4 posts holding the rear overhang have been replaced with douglass fir uprights skinned in 1/2 inch marine plywood and fiberglassed all over and tabbed to the deck. The longitudinal beams underwent the same treatment.  The pink colored putty you see is Awlgrips Awlfair.  The support posts have 5/8ths stainless rod running through the center, with stainless backing plates top and bottom to keep things firmly attached to the deck. The top nuts and coupler inside the beams are TIG welded in place so the only nut that could be tightened are those under the deck.  In the continued spirit of overkill, we mounted a backing block between the deck beams built up of laminated marine plywood, and installed a stainless strap across the blocking to the neighboring deck beams.  A similar stainless strap is mounted on the top end.

The rear posts and beams are ready for primer, and the 10 foot by x 9 foot center section is awaiting wiring for the stern light, deck lights, and speakers.  We have 2 sheets of 5 foot by 10 foot marine plywood waiting to be faired, primed and installed.

- Zach

Wednesday, April 10, 2013

New window frames Spring 2013

Noel is for Sale.

We are still actively working towards completion.

The front windows framing have been redone.  We replaced the sill, the support posts and all the internal framing.  I broke my camera for the demolition process, 

The sill is 2 inch thick mahogany, the posts are made of salt treated pine skinned in 1/2 inch plywood.  The window mouldings are made of 3/4 marine plywood.  The inner and outer top band was replaced with laminated plywood, 3/4 thick on the inside and 1/2 inch thick on the outside made of multiple layers.  Everything was then fiberglassed with epoxy and sanded to perfection currently awaiting window glass installation.  The outside trim is made out of PVC, filled, faired, sanded and painted to match the inner openings.  When the weather see's fit to give us 70 degrees night time temperatures the new glass will go in. 

We have the 3/8ths plywood skin for the roof overhang fitted.  15 sheets of 3/8ths marine grade, resin coated, sanded, primed and sanded... out to 220 grit.  They will be going up this week, glued and filleted in.

More pictures to come.