Wednesday, August 29, 2012

ALMOST THERE!! Two weeks of work.

Once again I haven't updated in the blog in a week or so... to much time spent working on the boat, not enough time to type updates. 

Lots has happened in the last few weeks, and I have had some great help.

Things that have been worked on:

After Simon and Shane worked on getting all the body fill sanded down on the deck I started to do the final coats of epoxy. 

I had been working Saturday and Sunday (18&19 of Aug) doing the final epoxy coats, Saturday afternoon halfway through coat 2 of 3- I ran out of epoxy.... The epoxy has to be done in succession as it's drying... if it's interrupted you have to let it completely cure, do a rough sanding and then do the rest of the coats....

Needless to say I got a little grumpy about this on Saturday afternoon, and took the last few hours off. However, there was a silver lining to this problem. I decided to revisit some of the deck hardware that was stubborn and wouldn't come off before. I got all the life line stanchions off and a few pulleys. 

Now with the deck entirely clear, I made my way to Noah's Marine Store (http://www.noahsmarine.com/index.asp) who have been exceptional in answering my many questions along the way, bought new epoxy and all of my caulking.

Through out the next week, I worked on re-sanding the deck and doing the final epoxy coat on the boat. On Tuesday Andrea came down and did an excellent job at finishing all the rough sanding under the water line, and Wednesday Nichola came and got half the rudder looking shinny and ready for painting!

Shane came down on Thursday and we worked until Monday on the boat. We got a ton done which was excellent. Shane worked on the finishing of the cockpit, sanding the body full and painted walls on Thursday and Friday. 

Saturday we epoxied the cock pit, and prepped all the deck to be caulked and sealed. We also started cleaning all the deck hardware.

Cleaning the deck hardware was a bit of a process until we found the magical paint remover. GOOF OFF! The hardware soaked in tin trays of goof off for 10-20mins and then with brass wire brushes we were able to get all the old paint and sealants off the hardware. It then took a bath in soapy water for 1-2hours, sprayed off with a hose and laid out in the sun for a few hours to totally bake out the moisture. 

Sunday was a very exiting day... relaying all of the deck hardware!! Learning how to use the Sikaflex caulking was a bitch... but works very well. With Sikaflex, you tape down a channel where you want the caulking to be, and the tape on either side protects what you don't want to be covered in caulking (if the Sikaflex touches anything it gets stained black).

Monday, Shane took a lot of time finishing chipping out old seam sealant on the hull while I taped off all the areas on the deck to be caulked. Throughout the evening I worked on caulking the deck, while Shane started to caulk the hull. 

Lots going on with the boat, but little left to finish:
- stern spinnaker winch mount rebuilt.
- hole in the starboard side filled
- some rotten wood on the port side taken out and replaced
- final coats of epoxy on the hull
- sanding down of the hull (fairing)
- Engine serviced (still looking for someone to do it!!!!)

PAINTING!!!

Looking like we may see the Wood Duck get wet this year... lets keep our fingers crossed. 




Teak floor of the cockpit has started to be sanded and the old caulking taken out of the seams. 

 Body fill in the cock pit to create a bit of a slope to get water off the bench. 

 Starboard deck all sanded down, epoxy already on the cabin walls. I left the fibreglass on the starboard side as it was still in very good condition. 


 The deck fully epoxied!!

Working in small spaces to get deck hardware off...yes my entire body was down in there.

Epoxy is sanded to give it tooth to be painted. 


 Another small space, taking off the spinnaker winch mount. 


The cock pit getting it's final sanding!

That little door in the back of the boat is where I was removing the spin winch.

Taped for epoxy.

Deck hardware taking a bath in Goof Off.

Little scrapping and brushing work station, with soapy wash bucket. 

Hardware baking to dry.

Assembly area for new bolts, washers, nuts and screws. 



Hardware waiting to go back on the boat.

The WOOD DUCK's name plate all shinny and new waiting to be put back on! 

Transmission lever's plate re-installed and cleaned.


 Deck hardware reinstalled on the aft of the boat.

Tapping out for the carpenter to replace the boards, the jagged lines are for "scarf joints" 

Chainplate covers sealed down.

Taping off the cockpit to be caulked. 

Me working on all of the tapping... soooo much taping. 



Close up of the caulking on the toe rail. This will be panted over also. 

Dr.Oz and Nurse Shane repaired my arm that the wood duck sign opened up.

Another picture of me taping... I did this for hours.



Shane's taping of the cracks in the hull to be caulked. 






Thursday, August 16, 2012

Wow! I am sorry it has been so long! Work has been happening on the boat throughout August and we are really starting to get near the finishing touches. I will try to re-cap everything that's happened on the boat over the last month, starting with the end of July at the beginning of the post.

Over the last few weeks, we have been ripping off all of the fibreglass from the deck. It had started pulling up in some areas and some areas had been damaged underneath by water and rot... So pull it all up! This was the itchiest few weeks of my life.

Once all the fibreglass had been pulled up, all areas where there was rot had to be chiselled out and the whole surface needed to be sanded to prepare for the epoxy.

Once everything was sanded and heavily cleaned, I started layering on epoxy body fill, which is mix of epoxy, cabosil and 3M bubbles which are tiny shards of glass. This mixture creates a peanut butter like fill that holds well into divots & holes. The main goal of this process was to fill the low areas, and refill the chiselled out rot areas. Both on the deck and the hull below the water line.

After days of body fill, everything needed to be precision sanded down to be even and level, because all small bumps etc will show through the final layer of epoxy. I was very fortunate to have to great people Simon Rossiter and Shane work a full day sanding down the whole deck.  The filler then needs to be covered over with 3-6 coats of liquid epoxy to seal it. The deck is a slow process, as you can only do little areas so you still have room to walk.

A brief summary of things left to do:
- cock pit sanded and smoothed out, then layers of epoxy coated on
- final layers of epoxy on parts of the deck
- stern spinnaker winch mount rebuilt.
- hole in the starboard side filled
- some rotten wood on the port side taken out and replaced
- final coats of epoxy on the hull
- sanding down of the hull
- sanding down of the epoxy on the deck

..... THEN PAINT!!! We are so very close to done. The last week and half and the next few weeks ahead are all the finishing stages of the boat. (oh... and clean the teak...)

Evan and I are hoping to have the boat in the water this September to run a few trials on the boat for a month and see how it fairs!

I will try to update more regularly.

o




Starting to pull off all the old fibreglass on the deck. 


The corn grows taller.

The majority of the fibreglass has been ripped off, which took around a week.


Sanding and cleaning up the deck.



The cockpit has half of it's fibreglass removed. 



There was a lot of fibreglass!


Cock pit is starting to look cleaner!


More fibreglass... I was sooo itchy. 


ALMOST THERE!




Roof of the cabin has some areas that need to be patched.

Starting the epoxy patches on the starboard hull. The epoxy is done is several layers, you first have to "wet it out" which is spreading liquid epoxy where you are going to do the body fill.


Laying down epoxy filler on the roof of the cabin.

Filling in areas of rot with epoxy filler on the fore deck.

Layers and layers of filler.

Epoxy patches on the side of the boat are done and ready for sanding. 


Helpful friend Charlie painstakingly sanding all the epoxy without creating flat areas. 

Roof of the cabin is starting to get smoothed out, working on rounding the edges into the cockpit. 


Large dip in the roof, building it up with epoxy to drain water better.


Epoxy fill areas being roughed up with electric sanders in preparation of the final layers of epoxy. 

The roof and fore deck all taped off to get final epoxy coating. 


Everywhere that is shinny is 3 layers of epoxy, leaving areas for walking around which will be completed later.