2007
Bobstay stay
3 Blade Prop and Sorry Rudder
Pintle & Gudgeon
Masthead
On the trailer
Going home
Home
Done
Cleaning the mess
More Ugly rudder
Can you see all the blisters?
Another bowsprit stay. Needs replacing
Forward thru hulls.
Big blister
More Blisters
First round of sanding to show blisters
Looks like the moon!
More filler from previous jobs
More Moon shots
Mahogany rudder
Big Blister
Blister's top
Blister Thickness... 1/8th inch
Covered
Covered 2
Side Cover
More Big Blisters
Boomkin removed
Rudder Removed
Naked Stern
More Naked Stern
Rudder Bolts
Rudder
Rudder Paint Removed
More Rudder
WORMS
MORE WORMS
Tasty
Floor under scuttle hatch
Forward Head Thruhulls
sink
More sink
Interior removal started
Boom
Boom 2
Bronze fittings
Bronze fittings 2
Pintles
Gudgeons
Wisker stays & Lower bowsprit stay
28 years of corrosion
Engine
Ice box
More kitchen
Removing beauty boards
Bare FG
Sink counter top
Oven gone
More beauty wood removed
Gel plane work to make quick work of the bottom.
More gel plane
Gel Planer
Boom Sanded
Portholes removed
Cleaned lower pintle
Winches
More gel plane pics
Looking down
Companionway header
View from Cockpit
Old chart table with waisted space below. Will be new icebox location.
Old sink area
Removing more stuff!
Forward section
More Forward section
Getting there!
Engine out!
Future clean bilge!
Need to remove motor mounts to mount new Fiberglass mount & pan from Cape George Cutters, the new builder of the BCC.
Icebox coming out!
More Forward view
YUCK!
Mast in the barn
Mast and other sailboat parts. Rudders, keels and misc boat parts for my Thistle & Fatty Knees,
GRINDING!
GRINDING
Nasty tabbing
More Tabbing
Tabbing almost removed
Settee hatch
Misc drawings of icebox location.
Settees removed
NAKED!
3M grip tape. Used for not sliding down side of hull when sitting there working above.
Icebox Bulkhead
Forward cabin bulkhead
Less stuff up here now
Exhaust fan on scuttle hatch
1/4 loose old tabbing.
Hand removal was common. Going...
Going...
Gone.
Bulkhead corners will need to be dremeled.
Speedo hole
Wet core around portholes
Looking from rear settee bulkhead back to rear of boat
1 of 15 like filled garbage cans. Look at all those tabbings that came out by hand!
Don't know what to do here. The white ship lap board has been glued onto the plywood bulkhead and now we can't get it off without destroying the bulkhead. UPDATE 12-20-08. Removed slowly using a small circular saw to kerf the ship-lap, then used a chisel to remove completely.
Old electronic mounting hole to be filled
Rear floor bulkheads for internally built water tanks. Removal necessary for new Plastic Water Tanks.
Bonfire of old boat parts! Note the pile on the left. Then the fire department came. Our fire was more than 4'x4'... more like 6'x15' tall! SMORE TIME!
Ship lap, kitchen counters, cupboards and rotten bulkheads!
Old Water tanks built into the floor. Note the plywood baffles.
More bilge bulkheads
Floors & Thru hulls gone
Water tank bulkheads removed. On to grinding!
Picture siting on Engine Mounts looking forward.
New Engine Mount. From Cape George Cutters.
Does it fit?
Clean
Clean and clear bilge. Old built in water tanks completely removed. SWEET!
Beer time
Nice new beer set up. Free beer with a sanded piece of wood.
Maria happy with her days work getting all old interior parts cleaned and prepped for reinstallation.
Trip to Cape George Cutters for some BCC parts. This hull mold is a Cape George 40.
BCC Mold
BCC Mold stern
Mocking up new Water Tanks. Forward tank on Right
Back Side of Tanks. Forward Tank on left.
Where they go.
Nice Fit!
Ready for the final piece to cover the ballast under the floors.
CPES on the forward bulkheads. Need more to finish. A fellow wooden boat owner mentioned CPES but said that you have to wait a week or more before you do any other bonding to it because it takes a bit to get the solvents out of the plywood. CPES absorbed VERY WELL and took close to 5 coats before it wouldn't accept anymore.
Floors covered. The only thing that will fit under these floors when we're all done is booze and maybe the folding storm anchor...?
The Lazarette that needs water channels!
Building a Water Channel Mold for Lazarette
1" of rise over 16" of run.
Good Fit with 1/4" oversized to accept the 1708 Biax cloth.
Ready to make the mold. More to come soon!
Finished part. Just about ready to be installed.
Mold and Part together.
So... how long does 6 gallons of Epoxy, 2 gallons of hardner, and 2 gallons of Clear Penetrating Epoxy last?... stay tuned.
New Oven/Sink bulkhead
Fitting the molded water channel.
Filliting
More Filliting
Settee Bottom in!
Tanks have arrived. At the last moment I had the tank maker remove the sharp corners on the top of the tank by 2 inches on each side while maintaining all other dimensions. This way I can easily remove around the floor beams.
Tanks longways. Total tankage: 18.5gal rear tank 26gal forward tank
Filling Through Hulls
Another Settee Shot
Tanks, Engine mount, & Settee fitting
TABBING!!!!! JOY!
More Tabbing!
Nice and bright bulkhead. This MAIN bulkhead was brought back to life(Bottom 1/4 was submerged for a bit) with a generous coating of CPES then MAS FLAG resin over the entire thing. Drilling the settee bottom in to this bulkhead REQUIRED a pilot hole as the surface was just too hard for a self tapping screw. JOY!
Side view of Fillet & Tabbing. Fillets were made with a long stick with a 1 1/2" washer attached to it. The other end of the stick has a 1" washer for any filleting on 1/2" ply.
Hatch that needed Water Channels. Was never really meant to be a hatch. The only thing keeping me from falling in the engine room were the 6 screws that made up the two hinges.
Water Channel Installed. Won't fall in now even without hinges.
Side View showing Channel. Yet to be faired and cleaned.
Slight mistake making the channel to deep in the rear. Deck core to be filled in with epoxy filler.
3/4 too deep. I'll shave the bottom of the deck to better match the bottom of the channel.
Filler between the front of channel and back of hull. The gap is no where near as wide as it looks. The top front could have been taller is my only regret on this project.
All Built
Underside Detail
Epoxy coating team takes over.
Routing out the core for thickened Epoxy.
Nasty stern tube.
The only thru hull I'm having a problem getting out.
The New Bobstay Fitting.
Back side of bobstay
Closing the old Hand Rail holes. Pilot holes on either side to make sure the core is dry.
Filling the core around the Port holes.
The inside of the porthole. Removing core and replacing with epoxy.
Found Wet Core all around 4 of the portholes. So far this looks like the only core issues. Let's hope that is all of it. The deck seems nice and water tight all things considered.
Lesson: Try to isolate the core anytime you put a hole through your boat!
OK... the last round of Epoxy didn't last too long so this time we have... 6 gal Thin Resin, 2 gal thick resin, 3 gal medium hardner, 1 gal fast hardner, 2, 10lbs bags of aerosil, 2 10lbs tubs of Milled Fiber, and 1 container of chopstrand.... JOY!
Pictured some of the rot before I removed it. Currently the wet core is removed and cleaned... Now I'll just leave it alone for a while to let it dry out completely and then finish the repair.
Sink Bulkhead ready to be installed in warmer weather.
Settee Backs fit. Still need to tab to hull.
Settee backs backside.
Built up a backing plate for the bobstay. A piece of 1/4" by 1" stainless steel will fit over this epoxy/plywood fill piece and be through bolted to the bobstay. Had to build up in the bow to accommodate for a wider backing plate. Still need to drill out bottom hole.
Sampson Post bulkhead ready for tabbing. After bobstay is totally complete and the weather warms up. (12-2-08)
Settee backs & Bottoms waiting for 50 Degrees to be installed.
Planks and cover boards removed.
Forpeak main bulkhead, & rear engine bulkhead waiting for 50 Degrees.
Spongy Block
More Rot
All removed and wet.
Planks removed on one side.
