Actual real life boat being built

Gel coat in the hull yesterday - first matt later today!

 

This thread is just so epic! Simply can't wait to see new images! Got one question, I see You guys used forklift to get the hull out from the mold, how did You "attach" the forklift to the hull?

 

Thanks!

The easy answer is anywhere we can - the plug is scrap afterwards so it doesn't have to be pretty and you need to tease it out so attaching it at different points is the way to go - We used lifting strops by the way!

 

Some photos of the balsa going in the bottom of the hull - the next stage is two layers of woven combi mat over the balsa, more balsa on the sides and the same layup over that then it's time for the "Hog", longits and engine bearers - the deck complete with screen plants is waxed up ready for gel now so it's coming along nicely!

 

The Kevlar thread is spreading the load of the central windscreen support, the "orange stuff" will provide a smooth transition between the main layup of the deck and the flange for the screen giving us the strongest possible support where it is needed.

The UIM specifications call for 50mm flange for a full cockpit boat (ours is a partial canopy), so we will stick to that.

 

Getting closer day by day to joining it all up and having a one piece boat!

More photos today - The large vents in the steps make a weak point in the hull, this is strengthened using over 6 kilometres or Kevlar thread laid into the side of the hull with epoxy to put the strength back in. The space between the layers of balsa is then filled to provide a level surface the put the next layer of combi mat on.

PS I hope somebody is reading this or are you all dumbstruck by the quality of work?

 

Looks great! End-grain slices, heh? I guess that maximizes the strength of the bond between the two layers of plastic.

Someone must be reading your posts, as you got a lot of positive votes against your name.

 

Awesome Project!

 

Wait wait, I don't get it -> dumb question -> You put balsa between Kevlar / fiberglass layers? So the hull will actually be made of both fiber materials and balsa?

 

Maybe I'm not explaining it very well - the photos should show there is a gap in the balsa for the Kevlar to sit in giving us a Kevlar/Epoxy beam to strengthen that area of the side of the hull - it's the yellow stuff in the first three photos. The rest of the boat is regular GRP.

 

Ah ok, I see now, thanks
By the way, what is the estimated deadline for this project?

 

As soon as possible!

We may be taking it to the London International Boat Show in January, and there is the "Brass Monkey" race in February which will be our first shakedown race - keep tuned!

 

Any updates? How thick will the hull eventually be after all this layering?

 

More updates - the first layer of the transom is in, the Hog is now cut (central longitudinal stiffener), the will butt up the the first part of the transom with the second part slotted to fit over the Hog, all laminated together with GRP - very strong construction!

We have put 1" Balsa in the bottom and thinner is the sides and deck, the bottom of the hull has Gel coat, first matt, two layers of woven 300X600 combi either side of the balsa which doesn't actually finish up being all that thick - without measuring it nearer 1 1/4" than 1 1/2" I would think. The main point being is it strong enough and the answer is without doubt!

 

First photo showing the central hog and engine bearers before being glassed in. The two halves of the boat are now being joined together in the mould giving us a seamless boat which not only looks good but is much stronger. The balsa will carry on up onto the deck, and you may be able to just see two balsa stiffeners on the upside down deck which will carry on down the side of the windscreen area to give strength there.