Finishing Up Stay Bulkheads

I needed to seal the exposed "endgrain" of all the laminated layers.  I decided to try using a slit section of carbon sleeve.  The knit sleeves tend to wrap nicely around corners.

Here is a shot of the wet-out carbon which took the shape pretty well.

I then layed the final covering layer of cloth over the edge of the sleeve.

These pictures show the final coat after un-bagging.  There is a little bit of print through from the sleeve edge.  Those two laminations should probably be done separately, so that the fringe of sleeve can be sanded flush.

These bulkheads are about done, though they will need urethane coating for UV protection where they are exposed above the deck.

Task time: 5 hours

Total project time: 309 hours

Fairing Stay Bulkheads

I decided I would fair in the cplate braces on the fore/aft stay bulkheads.  This would give it a little more finished look.  I added small strips of divinycell along the edges.

You can also see a flaw on the line to the left.  This was caused by using a piece of peel ply with a crease in it.  If you buy West System peel ply, get it bulk in rolls, not folded in bags.  Fiberglass Supply has a similar product in rolls.  It is impossible to get the creases to lay flat.

Once the epoxy was set, I sanded a bevel onto the foam.

There will be one light, cosmetic layer of carbon over the top.

Task time: 2 hours

Total project time: 304 hours

Carbon Work on Forestay Attachment

The fore/back stays are anchored on dedicated bulkheads which are strengthened with a combination of carbon plate and woven cloth.  There are three layers of cloth per side and then the cplate goes on. I believe the cplate was 18 layers making a total of 42 layers of reenforcement for the chainplates.

General Layout

Plate over carbon.  The nails act as locators.  Once glue has been applied the pieces are like a greased pig, so the nails allow you to find the proper position.

Plate faired and bagged.

Task time: 8 hours

Total project time: 302 hours

First Epoxy

I applied a coat of epoxy to some parts that don't get any fiberglass.  Start small.

Above are interior parts that form part of the pod/bunk area.

This is one of of the forestay bulkheads that will get three layers of carbon at the top, but is only coated with epoxy at the bottom.  You can see tabs/ears that will anchor the bulkhead to the main hull panels.  The notches are for spruce stringers.

Besides these parts, I spent most of the day sanding small pod/deck inserts.  These parts will be embedded in the foam core cabin top to support deck hardware and winches.  They are small bits that were nested in with much larger parts.  I decided to get them sanded and then I'll store them in bags until much later.

It has been ranging from the mid 20s to the mid 30s in town.  The heaters have been cranked up to get the shop up to 60F. The shop humidity is about 45% and a few couple larger panels on the top of the parts stacks are arcing slightly.  I'm trying to weigh those down.  A wood stove would probably drive the humidity out better.  The panels have been moved about five times in the last two weeks and have been in five storage areas.  The best storage was in Russell's shop for a few days.  He has excellent flat tables and a large wood stove.

Task Time: 6 hours

Project total time: 28 hours