Recess moulds

Somehow, I'm able to spend considerable amount of time on these moulds.  They each consists of five parts cut from 19mm MDF,  using a full size pattern which suggests larger moulds than the holes they are supposed to fit into.  Besides trimming in order to fit they also have to be trimmed and bevelled to fit the curved part of the beam mounts.  Then joined in a way that allows removal after laminating without cutting up the boat.  Then you just have to round the corners, apply releasable surface and find a way to fix them in place and - voila!  Hope to be ready for more laminations real soon.  I'm working on the four mounts more or less simultaneously, here showing the exterior of the aft port mould temporarily fitted using clamps and a spacer:

And the inside of the same, I have not fitted the small piece covering the inside of the "arm".  It is trimmed to fit, but I haven't figured out exactly how to fix that part in place, probably I'll try to just tape it in place with packaging tape and maybe some duct tape on the outside.

Beam mount taping started

The beam mounts will have to handle really heavy loads, according to the designer up to 4500 kg. Hence, he has done a lot of engineering to make sure they handle those loads.  This means that several reinforcements along load paths have to be laminated accurately and with care.  I have laminated some of the compression load reinforcements so far.  The need of making several moulds in the process means that this takes some time to do.  The newer version beam mounts are made in a way so fewer of simpler moulds have to be used.  This first picture shows the mould for the lower folding strut anchor flange provided with the beam mounts from Farrier Marine in place, and the flange laminated inside.  Just above the "arm", the exterior of the compression pad area is visible.

The first step of the inside laminations of the same area is showed here, opposite side.  This consists of several layers of bi-directional and uni-directional fibres. The area is formed against an outside mould made from full size patterns.

The rear lower folding strut bolting area after trimming flush with the hull:

Compression load path reinforcements added to the rear beam mount:

Last picture today showing port forward beam mount after trimming.  I have spent a few hours making moulds for the hull recesses surrounding the beam mounts, and still need a couple of hours to have them ready and in place.  Then the hull will be closed and the mounts further laminated on the inside, adding several more reinforcements.  It's a lot of work, but I really enjoy effectuating the fine engineering, and it will indeed be very strong and stiff.  Thinking of how Frimann is made, and the fact that she still sails after more than 35 years, makes me laugh from time to time.  This is a totally different story, I suspect this boat will survive anything.

Beam mounts in the hull

I got all four beam mounts tacked in.  I was very particular on getting the height and lateral placement correct but found that the bulkheads was so correct placed in the first place, that I didn't bother to check the vertical angle and just tacked the mounts firmly to the bulkhead.  The result is almost perfect.Phone camera picture showing aft side of starboard front beam mount tacked to the bulkhead:

Port front beam mount looking aft.

Port front beam mount from the outside.  Note there is no forward lower folding strut flange as seen in blogs from earlier builders like Menno and Jay.  Farrier is developing his design, and I got a middle stage in the beam mount development, now they are even easier to install. 

Now, using the lower folding strut bracket mould provided with the beam mount, I prepared to laminate the aft forward lower beam mount bracket.  This was a good time to adjust the one or so degree vertical misalignment, using a clamp between hull and mould.  I filled the gap between mould and hull with foam from the outside and filled and rounded transitions with epoxy/micro-balloons/silica from the inside. 

Then laminated the lower strut mounting flanges as per plan, using carbon rather than glass (same fabric weights), so they should be very beefy.

Cockpit view:

Trimming

It's not hard, but it does take time to trim and adjust everything in order to achieve exact alignment of the beam mounts, much as I have to go in and out of the boat all the time when removing the beam mounts for further trimming.  I guess I was 40 times in and out of the boat tonight.  However, everything is lined up correctly now and I'm ready to mix up some epoxy and stick them in place the next time.

Aft beam mounts with alignment jig:

Front beam mounts with alignment jig:

External view of front port beam mount and alignment jig:

Trial fitting beam mounts

I got the starboard side cutouts done today and was able to start trial fitting the aft beam mounts.  It seems there will be minor trimming of the beam bulkhead cuts needed before installation.  Picture showing aft beam mounts in place, held by beam mount alignment jig.  Hole in hull and bulkhead for starboard front beam mount visible in the background

Decent start on a new year

I have been able to make a decent start on this year, putting in a couple of working nights already preparing for the beam mount installations.  Only cell-phone built in camera picture quality however, as my camera died in the preparations to the last posting.

First, I had to level the boat in fore and aft and athwartships directions.  I cut my supports to keep the waterline rather than the gunwale line level, so I had to shim up the aft support.  First, to establish the exact position of the gunwale line at the beam bulkheads, I cut holes in the hull at those positions, as much energy was put in to achieve exact positioning of the beam bulkheads and thus their gunwale mark would be the best points to use in my boat.

Then, using extensions out trough these openings and a standard leveller inside to control athwartship alignment, I used a laser leveller to establish exact fore and aft alignment.  Packed up as requires as shown in the next picture.  Then I used a cardboard full size template for the cutout that I made from measures in the plan book, had a single light source several meters away and in combination with the laser leveller transferred the shape to the hull.  I used my oscillating saw to make small cuts each side of the bulkhead to control position of the pattern.  Then cut.

I still wonder about the window, as it seems to have come too close to the front beam mount, even though I am certain that I placed it to the best of my abilities according to plans.  Hmm.

Then I had to laminate the top flange extensions to the aft beam mounts.  This picture showing the beam mounts clamped to a "double mould plate":

And after the mould was removed:

I also had to make up the beam mount alignment jigs.  I cut them from MDF.  Used Guttorm's drill press to make the 3/4" beam mount location holes with a hole saw. 

At last the port side cutouts finished.  I dry fitted the beam mounts, everything seems to fit very well.  Tomorrow I'm going skiing with my son.

Happy new year!

I hope you all had a great Christmas and that Santa treated you all well, and I wish you all a happy 2010.  It has been slow on my boat building also the last month, but I have got a few small things done.  Most of my available time have been spent making blanks for the foil moulds.  It might not seem very impressive, and it is not, but it sure takes a lot of time to cut and glue these large size and heavy weight MDF pieces. Here are the rudder mould blanks.  These I am able to move.

The daggerboard blanks, however, are too heavy for me to move about and I will have to recruit some muscle to get them on the trailer and to the CNC machine.  They are both made up of three layers where I was just able to manoeuvre each of them to the lamination table.  Funny, I guess the main hull is lighter than each of these pieces.

I have been asked to publish a couple of pictures of the complete main hull, and I tried to take a picture like that today but I did not have the space nor the wide angle optics to make that happen.  My camera hit the concrete from +2m height and left this world in the process of trying though.  I have a few pictures from different angles, you will have to make up an image based on those. First the front showing the front beam bulkhead external reinforcement lamination being bagged.

The next picture is showing the cabin area, and underneath my form frame 5 and 8 position supports with towel paddings.  Made from 19mm MDF based on the full size patterns.  Turned out a bit wide in the upper area, leaving room for final adjustment when the hull is levelled for beam mount installation.  The front support is temporarily moved forward to give room for the reinforcement lamination.

Then the cockpit area.  The panels are ready, except for a few under seat dividers, and will be installed after beam mounts.

Aft end of the boat. The safety compartment hatch recess barely visible. Anchor well mould used as aft support. In the foreground the ply for the trailer bunk board.  To be epoxy glued 5 layers to the shape of the boat.

I am still very uncertain regarding the further progress, a bit frustrating as I have tons of motivation but no time, but my goal now is to sail the first regatta in August 2011.