Cracked Keel 1999 starcraft 2290

Hello
WOW Loooks like doing lots a work !
Turning boat up sode down is good makes life much easyer to work !! kae sure you gring off the gel coat where you wll be glassing !!glassing over gel coat is never good ideal must get glass to glass join!!!

 

Today we could not do much, electricity was cut
I was planning to make new foam with new wooden frames around it, then I realized that it is a hell of a job, therefore i decided to remove the old foam and use the same fiber mold. tomorrow we will continue and glass it and fill it with new foam
See the pictures

 

Going well !

Ok the foam shape you have is a good shape to get even more strength into the bottom of the boat !!

The vertical side closest to the keel is a good place to make a vertical stringer on edge simply glass chopped strand matt +2 layers of woven matt + on vertical face and down onto the hull 100mm , finish with chopped strand matt and go up and over the top of the foam . this is excellent way to get even even more ridged strength in the bottom of the hull this will add a little more weight but its being uses in a good place !!

Today we start to make 42 foot boat , Gell coat spray this afternoon and then start glassing tomorrow morning As we go throught the process i will send you pictures of what we are doing !!

 

It is not very clear to me, I am sure you noticed the empty space between the 2 molds, it is where the fuel tank sits, do you want me to do both sides only? how many stringers and where?
I appreciate if you draw it

 

Ok i will do a drawing when i get to work in the morning !!

 

Hi
For your ready reference
I am attaching again pictures for fuel tank in place before repair work started

 

6 mm wood tunnel above keel under fuel tank
see picture

 

If it is possible to shift these two parts a fraction so extra glass can be laminated it will be very beneficial to adding yet more stiffness to the hull bottom

 

Did you understand what i was saying about creating another stringer with the glass ? Just move the bit a little and make room for the tank !!
How is the tank mounted ?? What is it sitting on ??
Getting busy at my work so have less time to spend on computer . But will keep watching for you posts !!

 

Yes very clear, but i started to get worried about the extra weight, so far i used 80kg resin,60 kg glass and 15kg talc powder and still not finished, another 8kg foam and maby 10kg for the outside crack when i turn the hull.
The tank is sitting on a 6mm wood laminated with glass which i removed, you can see what left if it in the picture in my last post, I will be making it from new wood as it was all the way to the back.

 

Where does all that extra weight come from ??

When glassing resin is the one product that adds a lot of weight ! We are having the same problems with the boats we are making so i have gradually cut down on the amount of chopped strand matt being used and changed from woven matts to stitched matts along with all this i will gradually phase in the use of peel ply . This helps gets rid of even more resin from the laminate by compressing the glass as you roll it , the resin comes up through the peel ply and you have a much better looking layup and has far less resin . its almost as close to using a vac bag to compress the fibres and draw out surplus resin .
Easy to do and makes a really nice finish to work on after you tear the peel ply off and into the rubbish bin .
Match Racing yachts we use this method all the time during its construction throughout the manufacture of 8 boats we had a small variation of 20 kgs from the lightest boat to heavyest in 36 foot boats .
I am going to be fighting a long up hill battle with all the staff all the time where i am here in china .
They have made some boats from the ready made parts that came in the moulds that they bought and they are now have boats that are out of ballance and tail heavy because of over sized motors that had been specified and extra glass here and there and doubling up laminants and not thinking !!!. :idea:

 

OK, I got it now, from your long experince do you think that this boat will not leack water again from same place?
How many more years I can still use it without problems?
I could not continue the repair work since last sunday, I hope to start again tomorrow and post new pictures.

 

Provided you have glassed all the strakes as i discribed you should never have any problems again The glassing is really the responsability of the guys doing the job . Trying to do a step by step thousands of kilometers away leaves a few unanswered questions . I would have done some things you have done differant if i had been on the spot but it will be 100 % better than it was any way .
I personally feel the boat has had a hard life and been badly abuse during its life time !!.
The trailer is something i would seriously look at modifying to support the hull bottom better !. Its why i said to double up the layers of glass in the keel !!, the keel could and would be able to take 80% of the total weight of the whole boat and the other 20% on the beds to support the hull where the strakes are and all the newly glassed area .
Theres a reason for everything and everything is done for a reason !!!, Some time not evident at the time of doing the job but later when it comes time to modify the trailer beds !!

Good luck !!

 

Today I glassed the foam molde
See pictures

 

more pictures for today
Tomorrow we will try to fill the foam and do the tunel under fuel tank and the rest
after tomorrow we will turn the hull upside down to do the outside also
Will keep posting with pictures work progress
Thnks for your support