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And So It Begins Again

Discussion in 'Paddling' started by DaveRT, Jun 9, 2016.

  1. Thadf

    Thadf Tracker

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    You had me licking my chops right up to the brussel sprouts!! I've tried hard to like them, but life is too short for that!!!

    Great work , as always.
     
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  2. DaveRT

    DaveRT Supporter Supporter

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    Update on my kayak build. After sanding the deck and seams smooth, I came up with this.

    IMG_2657.JPG
    With a little bit of duct tape and a desire to reduce the dust in my garage, I've connected my shop vacuum to my sander. Redneck dust collection system.

    IMG_2658.JPG
    I'm filling in the little gaps in the seams with thickened epoxy. If left unfilled, it would show up under the fiberglass as a white spot. This also would weaken the strength of the seam.

    IMG_2659.JPG
    More time here will be worth it in the end. Tomorrow after sanding these blemishes, I will roll on a saturation coat of epoxy.

    IMG_8949.JPG
    How many deer do you see? All the does here are pregnant. Very common here to have twins. There were 2 sets of triplets last season. You could be looking at a dozen deer.
     
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  3. DaveRT

    DaveRT Supporter Supporter

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    Up early and at it. Two hours later, I'm done working on the kayak for today.

    IMG_2664.JPG
    Finished up sanding all the spots I touched up with thickened epoxy yesterday. Cleaned up garage and went to work rolling on the saturation coat of epoxy.

    IMG_2671.JPG

    With that step completed, next is to go over all of the fresh epoxy with a dry foam brush. This breaks the tiny air bubbles caused by the foam roller. Makes a much smoother finish to the epoxy.

    IMG_2677.JPG The saturation coat really brings out the detail of all the seams.

    IMG_2681.JPG
    This is the area behind the seat. Many hours went into this area. Remember making the deck with the 2 layers of fiberglass laminated to the underside.

    IMG_2673.JPG
    The holes left by the wires look like snake bites.

    IMG_2675.JPG
    I'm happy with the way the pointy ends came out. This is the bow.

    IMG_2688.JPG
    This is the stern.

    IMG_2679.JPG
    The saturation coat really brings out the character of the wood. Pygmy does a great job of cutting the panels from one sheet to keep the grain matching when assembled.

    IMG_2683.JPG
    Difficult to eliminate the reflections in the pictures.

    IMG_2684.JPG
    Next step is to lay out the fiberglass cloth and trim. Then laminate with epoxy.
     
  4. Thadf

    Thadf Tracker

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    Damn that looks cool!!
     
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  5. DaveRT

    DaveRT Supporter Supporter

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    Up and at it again this morning. Today I fiberglassed the deck.

    IMG_2711.JPG
    Started by laying out the masking tape 1 inch below the sheer seam all the way around hull.

    IMG_2714.JPG

    Smoothing out the fiberglass cloth and trimming.

    IMG_2717.JPG
    This step went well, I haven't started to itch yet.

    IMG_2725.JPG
    Mix up the epoxy and starting from the center, wet out the cloth with a roller.

    IMG_2728.JPG
    After each batch of epoxy, squeegee the excess off the cloth making sure you don't have any lifting at the seams.

    IMG_2729.JPG
    Two batches of epoxy got me this far.

    IMG_2732.JPG

    The area behind the seat took extra time to smooth out.

    IMG_2737.JPG
    IMG_2730.JPG
    Glad to have this step completed. 5 hours without a break got it done including cleaning up. In a few hours I will be able to cut above the masking tape and pull off the raw edge of the fiberglass cloth. Tomorrow the first fill coat of epoxy will be applied.

    IMG_8981.JPG

    When you get up at 4:30 in the morning, you never know what your going to see. The deer were just leaving the vineyard after having their breakfast.
     
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  6. DaveRT

    DaveRT Supporter Supporter

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    Today the kayak got its first fill coat of epoxy. I trimmed above the blue masking tape with a utility knife and removed the raw edge of fiberglass without issue.

    IMG_2801.JPG
    The weave of the fiberglass cloth can still be seen, the next coat of epoxy should smooth out the fiberglass surface.

    IMG_2806.JPG
    The next coat will leave enough epoxy to sand without cutting the fiberglass.

    IMG_2804.JPG
    Happy with the pointy ends.

    IMG_2755.JPG
    After the post on Saturday, I was lucky and bagged a 20 pound Tom.
     
  7. DaveRT

    DaveRT Supporter Supporter

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    Continuing onto fitting and trimming lower coaming pieces today.

    IMG_2815.JPG
    One side is fitted flush with inside edge of cockpit and clamped in place. Guide lines are made on the coaming half lining up with the center deck seams.

    IMG_2816.JPG
    Using a draw saw, the ends are trimmed.

    IMG_2817.JPG
    The half is removed and the step is repeated on the other side of the cockpit with the other lower coaming half. Then both halfs are set in place for final sanding for a tight fit.

    IMG_2818.JPG
    Both lower coaming pieces can now be coated with epoxy before securing to deck.

    IMG_2819.JPG

    Here you can see the 2 other pieces of coaming on the bottom of the picture. These upper pieces will be laminated in fiberglass and epoxy, than trimmed to fit like the lower coaming pieces.
     
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  8. Doubles

    Doubles BCUSA Friend Bushcraft Friend

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    It may have been answered earlier in this build, or the previous one....roughly how many hours do you have invested in the project, start to finish?
     
  9. DaveRT

    DaveRT Supporter Supporter

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    I'm retired and do this for enjoyment, so I don't rush. Pygmy says around 100 hours of building time. 6 to 8 weeks in reality. You have to wait for the epoxy to cure before moving on to the next step. You do a hours work and have to leave it for the next day to go on. On my first kayak I believe Pygmy's is spot on saying 100 hours. I started this one a year ago. Life gets in the way. Pygmy runs schools to build one. They almost complete it in the week class. By then you are skilled to the point where you can finish it up at home on your own.
     
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  10. Seeker

    Seeker Woods Bum Supporter Bushclass I

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    fwiw, I have 80 hours in my stitch and glue canoe, and it's not nearly as polished as this work of art... and yeah, a lot of it was "glue and wait" time... took about 2 months for me to finish.
     
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  11. DaveRT

    DaveRT Supporter Supporter

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    Spent 1 1/2 hours preparing work space. Covered with freeze paper. Cut fiberglass cloth to fit upper coaming pieces. Sanded all coaming pieces. Laminated one side of the two upper pieces. Epoxied both lower pieces. Cleaned up. That's it for today. Tomorrow repeat the process.

    IMG_2823.JPG J
    IMG_2824.JPG
    IMG_2827.JPG
    IMG_2829.JPG
     

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  12. DaveRT

    DaveRT Supporter Supporter

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    After the second coat of epoxy hardened up on the lower coaming pieces, I dry fit it to cockpit. Sanded contact area and spread on the thickened epoxy. Aligning and securing with clamps went well.

    IMG_2843.JPG
    Dry fitting.

    IMG_2852.JPG
    The cockpit epoxy needed sanding. Found all my clamps.

    IMG_2856.JPG
    Mixed up some thickened epoxy and spread on deck and coaming pieces.

    IMG_2857.JPG
    Alignment is slightly different due to thickness of epoxy. Also slippery.
    IMG_2865.JPG

    Can never have enough clamps.
    IMG_2861.JPG

    IMG_2863.JPG
    clean up time spent now on the squeezed out epoxy saves a lot of sanding time later.

    IMG_2851.JPG
    The upper coaming pieces have been laminated on both sides, trimmed and sanded. Next step will be bonding them to the lower coaming now in place when cured.

    IMG_2837.JPG
    IMG_2838.JPG
    The coaming work is the short job. Mowing the lawn is the long job. It does help pass the time waiting for the epoxy to cure between steps.
     
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  13. Thadf

    Thadf Tracker

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    Beautiful........kayak and lawn
     
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  14. DaveRT

    DaveRT Supporter Supporter

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    With lower coaming in place, upper coaming goes on today.

    IMG_2866.JPG
    This is how it looks after the clamps came off.

    IMG_2871.JPG
    The upper pieces are trimmed in place. The first is trimmed with a saw.

    IMG_2872.JPG
    It's trimmed to centerline of deck.

    IMG_2878.JPG
    The other half is aligned and overlaps the first half. It's cut with a utility knife to tightly butt up against the other side.

    IMG_2879.JPG
    Everything is dry fitted before mixing up the thickened epoxy. A little filing and sanding get it square.

    IMG_2881.JPG
    With the two pieces coated with thickened epoxy, they are aligned and clamped. Yes I need more hands. Yes it is messy. Yes I have epoxy on my iPhone.

    IMG_2882.JPG
    Again I use all my clamps.

    IMG_2883.JPG
    Needed to shim one front edge to have the plywood veneers align. Mylar keeps the shim from becoming part of my kayak.

    IMG_2886.JPG
    Hurry up and wait.

    IMG_2891.JPG
    This is farm country. They pooped the fields today. So far I have been upwind. Tomorrow????
     
    Last edited: May 22, 2017
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  15. DaveRT

    DaveRT Supporter Supporter

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    Now this is what a coaming is supposed to look like.

    IMG_2897.JPG
    These shots are just after the first coat of epoxy. It's still wet.

    IMG_2898.JPG
    I'm happy it's done.

    IMG_2899.JPG
    It will get a few more fill coats before final sanding.

    IMG_2900.JPG
    I'm glad I used the shim to line up the veneers yesterday.

    IMG_2906.JPG
    This is the view that Char will see when paddling. It had to be right.

    IMG_2908.JPG
    Laminated one side of the piece that will become the seat mounting, hip and deck supports.

    IMG_2909.JPG
    More epoxying tomorrow.

    IMG_2895.JPG
    Corn being planted today in the field beside my back yard. Makes a great food plot to draw in the deer. Yum!
     
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  16. Thadf

    Thadf Tracker

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    I've already decided that I can't do it. I don't have the patience for the tediousness. You make it look easy, it I know better!

    Looking great.
     
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  17. DaveRT

    DaveRT Supporter Supporter

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    In a way, I've failed. I have always hoped that my posts would inspire others to give it a try. If I can do it, than anyone can. I'm a retired machinist, not a woodworker. I also did these projects as a challenge. I can't sing or dance. Music, I can't even clap my hands to the beat. I do enjoy watching others do what I can't. So I do hear you. Thanks for watching.
     
  18. Bad Little Falls

    Bad Little Falls Guide

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    You sing a different note. I can relate to the musical ineptness. Nice project!
     
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  19. DaveRT

    DaveRT Supporter Supporter

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    It's the little things. That take so long.

    IMG_2908.JPG
    After being laminated, this piece can be made into two seat supports.

    IMG_2912.JPG
    Measurements were laid out in cockpit to locate the brace. Traced line on backside and cut with saw.

    IMG_2910.JPG
    Piece was filed and sanded to fit. Same done for other side.

    IMG_2916.JPG
    Pygmy supplies a hull number when shipped. They registered it with the Coast Guard. I burned it into the seat brace. It will be behind the back support when in place.

    IMG_2925.JPG
    It's also burned into the stern, starboard side. Both places will be coated with epoxy. Later I will also do the bulkheads.

    IMG_2921.JPG They are glassed in place with thickened epoxy and fiberglass. Messy job.

    IMG_2920.JPG
    Everything gets a coat of epoxy.

    IMG_2926.JPG
    The reflections in the photo don't do it justice. It came out fine. Tomorrow when cured, I will be able to drill holes for the backrest pivots. Finally machinists work, even if it is into wood and not metal.
     
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  20. DaveRT

    DaveRT Supporter Supporter

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    Assembled seat backrest and installed to check fit this morning.

    IMG_2927.JPG
    IMG_2930.JPG
    Just to check fit, will remove to install rear bulkhead and adjustment hardware.

    IMG_2934.JPG
    On to the next step, hatch installation. Layout measurements with tape, trim spacers with saw.

    IMG_2936.JPG
    Trace line onto tape.

    IMG_2940.JPG
    Drill a few holes as close together as you can on cut line.

    IMG_2941.JPG
    Scratch saw blade carefully over holes.

    IMG_2942.JPG
    Presto, saw is thru deck.

    IMG_2944.JPG
    My redneck setup to blow the sawdust off cut line so I can see what I'm doing.

    IMG_2946.JPG
    One down, one to go.

    IMG_2950.JPG
    This is just the start. Many steps left to complete the hatch job. Hope everyone has a nice holiday this weekend.
     
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  21. Finner

    Finner Supporter Supporter Banned

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    Just outstanding
     
  22. CampCowan

    CampCowan Wabi Sabi Supporter Bushcraft Friend

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    Wow, really looking good. Cutting into that beautiful boat would make my heart skip a beat.
     
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  23. DaveRT

    DaveRT Supporter Supporter

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    Inside sheer seam and sanding today.

    IMG_2960.JPG
    Sanded both bulkheads to fit, cut all pairs of hatch spacers and lips, sanded them smooth as well as inside hatches. Tomorrow they might all be laminated with fiberglass.

    IMG_2959.JPG
    Rigged kayak on side to have the inside sheer seam on bottom, gravity helps the thickened epoxy settle into seam.

    IMG_2961.JPG
    This is a syringe taped to board to reach up into the pointy ends. A dowel passed thru screw eyes pushes on the plunger to squeeze out the epoxy. Works fine. I made up this one when I built my first kayak.

    IMG_2966.JPG
    Thickened epoxy in seam. Area sanded before I epoxied deck on weeks ago.

    IMG_2967.JPG
    Tape being laid over the wet epoxy.

    IMG_2968.JPG
    Tape wetted out. Tomorrow turn kayak up onto other side and repeat.

    IMG_9010.JPG
    I was up early yesterday to start work on the kayak. I was lucky to get a few shots of a doe and her new born hours old fawn.

    IMG_9009.JPG
    Maybe it will grow up to be a giant buck and end up on my dinner plate.
     

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  24. DarrylM

    DarrylM Guide

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    That long reach syringe extender looks like just the ticket for reaching all the way into the pointy ends.
     
  25. DaveRT

    DaveRT Supporter Supporter

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    Here is a picture from the first build.
    IMGP4883.JPG
     
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  26. DaveRT

    DaveRT Supporter Supporter

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    Like the shampoo bottle says, repeat as nessasary.

    image.jpeg
    With kayak on other side, I completed the inside sheer seam. Started cutting fiberglass cloth to fit hatch covers and bulkheads.

    image.jpeg
    As suggested by Thadf, the work can get tedious. I sometimes look forward to the curing time. Than I can spend 3 hours cutting and trimming the lawn. I did get a chance to put 120 rounds thru a few of my handguns. Also helps to be retired. I have been able to walk away at those times and return when in a better mind set.

    image.jpeg
    Almost need a larger work table.

    image.jpeg
    Freezer paper shinny side up keeps the epoxy from bonding to table. The bulkheads will make the fore and aft compartments watertight as well as add strength. Foam tape will seal against hatch covers to complete the seal. Without the watertight compartments, the kayak could sink. The fiberglass and epoxy added weight overcome the buoyancy of the 4 mil. oakam plywood. Good to know.
     
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  27. DaveRT

    DaveRT Supporter Supporter

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    Ding! Round 2

    IMG_2982.JPG

    IMG_2984.JPG

    IMG_2986.JPG
    Tomorrow, backside of the hatch lips will get laminated. Bulkheads should be installed. The spacers lip spacers will be epoxied into hatch openings. When cured the lips will go in.
     
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  28. Thadf

    Thadf Tracker

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    Looks great, I can't wait to see you in it on the water!!!
     
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  29. DaveRT

    DaveRT Supporter Supporter

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    Didn't go as planned. More time spent sanding than I remember spent on the first kayak build.

    IMG_3017.JPG
    Bow bulkhead looking after through forward hatch. Dry fit and sanded for epoxying.

    IMG_3029.JPG
    Looking forward from cockpit.

    IMG_3030.JPG
    Again looking through forward hatch with thickened epoxy and fiberglass tape ready to be wetted out.

    IMG_3038.JPG
    All epoxied in place. Hard area to take photos in. Tomorrow on to the aft bulkhead.
     
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  30. DaveRT

    DaveRT Supporter Supporter

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    Up early today. Bucky Jr. is watching me eat my brook trout for breakfast. Installed the spacer in the forward hatch opening. Can't work on an empty stomach.

    IMG_9023.JPG
    You can just see the start of his antlers.

    IMG_3045.JPG
    My good friend dropped off this brookie last night. Yum.

    IMG_3046.JPG
    Spreading the thickened epoxy onto spacer.

    IMG_3047.JPG
    Clamp city.

    IMG_3048.JPG
    Much easier than it looks. Tomorrow I will start on the aft hatch and bulkhead. Thanks for watching.
     
  31. DaveRT

    DaveRT Supporter Supporter

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    Man in brown delivered the goods, so I'm back in business.

    IMG_3050.JPG
    Dry fitting the lip on forward hatch.

    IMG_3060.JPG This is the lip being epoxied to the spacer I epoxied on the day before.

    IMG_3061.JPG
    A foam strip will be cemented onto this lip to seal against the hatch cover for water tightness.

    IMG_3062.JPG
    Aft bulkhead is located at the rear of the cockpit behind the backrest. I've just finished putting a filet of thickened epoxy around the edge where it contacts the hull and deck.

    IMG_3065.JPG
    As with the forward bulkhead, the aft one gets taped and wetted out with epoxy.

    IMG_3068.JPG
    This side is completed, tomorrow I should do the other side working through the aft hatch opening.

    IMG_3067.JPG
    With a strip of wood tapped to the brush, I'm able to seal the backside of the forward bulkhead with the rest of the epoxy.

    IMG_3057.JPG
    Had the back and side lots cut today.
     
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  32. CampCowan

    CampCowan Wabi Sabi Supporter Bushcraft Friend

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    I get lightheaded just looking at all of the epoxy. How are you dealing with the fumes?
     
  33. DaveRT

    DaveRT Supporter Supporter

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    The garage thermostat is set to 63 degrees which keeps helps keep the fumes down. Higher temperatures and I sweat while working. Above 65 degrees and I open both garage doors. When the epoxy is curing, I'm out of the garage. Still have all my hair, but it's white. I blame that on being 65. I wear long sleeve shirts and rubber gloves at all times, shower when done. I still itch.
     
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  34. DaveRT

    DaveRT Supporter Supporter

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    6 hours lawn care and trail mowing, 2 hours kayak work.

    IMG_3085.JPG
    Forward hatch opening with spacer and lip epoxied in place.

    IMG_3086.JPG
    A foam strip will go onto this lip next.

    IMG_3083.JPG
    Without boring everyone, this is the aft bulkhead's backside epoxied in place. Same steps as yesterday.

    IMG_3070.JPG
    This morning they tedded the mowed grass from yesterday's cutting.

    IMG_3077.JPG
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    They returned after lunch and took it all away to feed the dairy cows.

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    I was up early this morning and caught this doe feeding her fawn. This doe cuts out the middleman and makes her own milk from the same grass that the farmer feeds the cows.
     
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  35. Thadf

    Thadf Tracker

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    You taking vacation?

    Hope this finds you well.
     
  36. DaveRT

    DaveRT Supporter Supporter

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    Yes, only we didn't go anywhere. My Retired friends visit in their motor coach every year from Ohio. More friends from Florida. Trips to the airport, lots of lobster and beer. Late nights catching up. A house full. Life gets in the way again, but in a good way. Will be back to the build later today. Thanks for checking.
     
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  37. DaveRT

    DaveRT Supporter Supporter

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    Back at it.

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    After a dry fit check, I've bonded the spacer lip to the rear hatch opening.

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    Should be cured by tomorrow so I can dry fit the lips in place.

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    The cleaner you work, the less sanding in the end.

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    In the meantime I return to the forward hatch. I do the marking on painters masking tape. Here I'm locating the holes for attaching the straps that secure the hatch cover.
     
  38. Thadf

    Thadf Tracker

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    Way to go!

    Sounds like you have good friends too!!
     
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  39. DaveRT

    DaveRT Supporter Supporter

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    It's the little things that I'm dealing with now.

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    Aft hatch lip epoxied to spacer.

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    After curing overnight, I removed clamps, scraped and sanded, got ready for next step.

    IMG_3150.JPG Two layers of fiberglass tape are epoxied up and under the seam of where the lips join. I have also done this on the forward opening.

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    Foam strip will complete the opening tomorrow. Maybe.

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    Located the position for the strap mounting holes and drilled. Here I'm using a pipe cleaner with epoxy to seal the edges of the holes. Q-Tips are to big.

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    This is a clamp holding a pad eye to the underside of the cockpit coaming so I can mark the drilling spots. This pad eye is use to support the rear of the seat backrest.

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    I use a small mirror like a dentist to work upside down. A line will connect to the backrest and then to a small cleat on the side deck. I will be able to adjust the angle while seated in the cockpit.

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    This mornings deer picture. She is looking for her fawn.
     
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  40. DaveRT

    DaveRT Supporter Supporter

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    More little things.

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    Foam gasket install today. Started by sanding lips for a better bond with the contact cement.

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    Contact cement is applied to both lip and foam, left to dry for a few minutes. The foam strip is placed around the lip carefully forming it around the corners. Cut the extra off and butt the two ends together. Sticks like glue. (Sorry, I had to say it.)

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    Same deal on the forward hatch opening.

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    Measured twice and cut a dozen spacers for the hatches. They go under the straps to hold the edges down.

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    Sanded a bevel on two of them.

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    With the bevel your fingers can grab the cover to remove. Sanded the others and then stained all twelve.
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    Assembled the hold down straps and cams.

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    The straps will hold the half dowels in place tomorrow when they might get epoxied on. All the hardware comes off for the sand to varnish operation.

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    The end of the straps will be trimmed after the final fitting.

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    Far from finished, but I do feel closer.
     
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  41. DaveRT

    DaveRT Supporter Supporter

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    Can't wait to pull a cold beer out of the hatch some day.

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    Sanded both hatch covers. Marked positions for all the dowels. Mixed up the thickened epoxy and bonded dowels to covers.

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    Tightened straps to hold dowels while the epoxy cures.

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    Don't forget the aft hatch. Repeat the procedure here.

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    Tomorrow, coat the bonded dowels with epoxy.
     
  42. CampCowan

    CampCowan Wabi Sabi Supporter Bushcraft Friend

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    Wow, it looks like you are getting very close to completion. Such an elegant boat, really well done. I am always happy to see updates to this thread.
     
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  43. DaveRT

    DaveRT Supporter Supporter

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    Today's update.

    IMG_3193.JPG
    Removed hatch covers with the now bonded half dowels as well as attached hold down straps.

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    Epoxy coated the dowels.

    IMG_3201.JPG
    Started a little sanding on the deck. The homemade dust collector works fine.
     
  44. DaveRT

    DaveRT Supporter Supporter

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    What a day for a end pour.

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    Char finally gets to help.

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    Made up a support from scrap 2 by4s and clamped it to the barn.

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    Poured 4 1/2 Oz. of thickened epoxy down the hatch. The bucket is full of water to cool the epoxy as it cures. 75 Deg. day. Water 68 Deg. Epoxy 93 Deg.
     
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  45. DaveRT

    DaveRT Supporter Supporter

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    Like your kids, what you do for one you do for the other. We turned the kayak around and did the end pour in the stern.

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    Had help to swap ends, but lost her at photo time.

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    Will leave out overnight. Will bring inside first thing in morning. Rain forecast tomorrow.

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    Epoxied pad eyes to inside of both hatch covers. I will a line to keep covers attached to kayak.
     
  46. Thadf

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    That's very interesting the way the ends are sealed.
     
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  47. DaveRT

    DaveRT Supporter Supporter

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    The ends are sealed and strong enough as they are. With epoxy in the ends I can drill a 1/2 inch hole through the hull and have it remain water tight. Deck rigging, carry handles, bow line can than be attached. Thanks for watching.
     
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  48. CampCowan

    CampCowan Wabi Sabi Supporter Bushcraft Friend

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    Thanks for explaining that, I was wondering too. I had no idea the length of your boat till that shot. That thing is going to really scoot.
     
  49. DaveRT

    DaveRT Supporter Supporter

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    14 1/2 feet. My first one is 17 feet.
     
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  50. DaveRT

    DaveRT Supporter Supporter

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    We got up early to bring the kayak inside before the rain ☔️. Rewarded with a photo opportunity. Milk fed veal, oops I mean, tender venison, oops I mean tender moment in nature.
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    More sanding of deck, coaming, and hatch covers. Almost ready to flip over to sand hull.
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    Did drill holes in the pointy ends.
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    Looks like a shark
     
    Last edited: Jun 23, 2017
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