Exterior

Requirement: protect the exterior as much as possible to minimise maintenance and cost in the future.

Hull

Underwater

  • Drilled propeller hole

  • Drilled exhaust hole

  • Drilled water filter hole through the hull below waterline

  • Eco sounder - cut a hole in the bottom and make it solid fibreglass & epoxy as the echo sounder does not work well through the wood. Glued the transducer on top of that. 

  • Shaped the stern for the propeller, fibreglass, epoxied etc

  • Added wood to the stem to make it rounded 

  • Measured and raised the waterline 10 cm / 4” (hope it does not disappear when launched) 

  • Epoxy glue waterline with a string

  • Fitted series drogue plates: 10 mm stainless steel plate - 40 cm long,  with 4 mm SS backing plate

Finish

  • Epoxy to the hull at the time of build, sanded

  • 2 coats of epoxy, sanded

  • 2 coats of epoxy primer, sanded 

  • 5 coats of epoxy and copper coat powder mix applied in one day to bond well

  • Sanded before launch to expose copper

Topsides

  • Cut out 2 windows port and starboard and 2 aft

  • Epoxy coated at the time of build and painted to a high standard. This needed no attention at the time. We only needed to paint to our colour scheme. 

  • Two epoxy undercoat paint, plus two polyurethane paint 

Bow and Side Decks

  • Sanded back the paint

  • Epoxy fibreglass  

  • Epoxy undercoat x 2

  • Non slip paint ​​​

Shoe
Decks
  • Steal shoe by design discarded as maintenance issue

  • Measure and dry fit plywood shoe (25 mm), rout edges

  • Fibreglass & epoxy plywood shoe to the bottom of the keel

  • Fit to the keel with epoxy glue 

Side decks

  • Repair damaged plywood in places

  • Fibreglass bow and side decks

  • Filled the stanchions at deck level to stop water collecting

  • Filled gaps near the aft step - to stop the rot

Bulwarks 

  • Repaired plywood

  • Drilled new eye in the bow and made a ring - epoxied

Cabin
  • Repair damaged plywood areas on the cabin top 

  • Made pattern for plywood to fit on cabin sides on original sepilea, cut plywood

  • Epoxied glue plywood to the cabin & screwed

  • Coated plywood with epoxy 

  • Filled the screws & filleted cabin to deck ‘joint’ 

  • Epoxy undercoat x 2 - Painted x 2 

  • Windows - build up window sills to drain overboard

  • Hatch FWD - made frame, replaced the hatch

Hatch

  • Tufnol sliding runners

  • Hatch inspection opening - for maintenance

  • Hatch diamond window closed with polycarbonate

  • New polycarbonate wash board

Cuddy

  • Designed and built a sliding cuddy above the bridge deck

Cabin - topsides

  • Vents - made ring, fitted

  • Chimneys - made rings, fitted

  • Grab rails - painted 

  • Window shutters - cut diamond window shape and rebate for polycarbonate, paint and glaze

Cockpit

Lockers

  • Inside: Fibreglass cockpit deck inside lockers and cockpit deck edges (joining lockers and bulwarks), epoxy undercoats and epoxy paint finish

  • Series drogue - Cut holes for series drogue access

  • Two air ventilators for saloon

  • Outside: epoxied lockers sides and fibreglass locker base edges to the cockpit deck (5 cm) for water drains channel

  • Lids:  cut new from plywood, epoxy glue Douglas Fir decking veneer down 

Cockpit deck:

  • Belt sand and epoxy glue Douglas Fir decking veneer down (Gougeon brothers method) 

  • Filled corners close to the frames to stop waterlog & help drainage

  • Deck light - drilled holes, glue polycarbonate with UHB tape

Bulwarks cut down all round the top sides and reinforce with plywood where cut bullworks

  • Shaved off bottom aft bulwark to fit the rudder & self steering / trim tab

Davits 

  • Fit through aft bulwark / epoxy / paint -  bolt on davits 

Steering & Self Steering

Rudder

  • Build rudder head 

  • Metal fittings to the hull and rudder

  • Propeller cut-out

  • Fibreglass

  • Dry fitted

  • Added trimtab

  • Trimmed aft bulwark beam to fit trim tab

  • Add end plate to rudder

Tiller

  • Make and fit tiller joint to rudder head

  • Make hinge plate for tiller connection

Self Steering

  • Build Bill Belcher OTG 2

  • Connected to trim tab on the rudder

Masts

Masts are reinforced with unidirectional fibreglass:

  • Unidirectional fibreglass - 3 layers, tapered

  • Epoxied with aluminium graphite to strengthen 

  • Fitted heal to mast step ( FWD 11% and main 7%)

  • Mast heal - epoxied 

  • Mast cap- 18 mm plywood, biaxial fibreglass top & bottom, glued and screwed to mast head, filleted & fibreglass under the cap.

Masts Head
  • U bolts, glued and screwed - 3 for rigging

  • Glue leather to protect the wood

  • Mast top Main Mast - 7% sloping lights base - the light had to point horizontally!

  • Mast top FWD Mast - 11% sloping base for Burgee 

  • Burgee made of plastic ring to plastic swivel, fitted onto fibreglass tube

Masts Step