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Joined Nov 2005
370 Posts
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The Hull - Fitting the Bowsprint
While waiting for the special varnish I ordered to arrive so I can finish the deck furnishings, I have started on the hull. I have some doubts about working with fiberglass as I have no experience with it, and I have read that it can chip and burr if you don't have the correct tools. They recommend drills ground to a 90 degree included angle, and say that tools dull very quickly. Well, I am still waiting for my drills to come back from the sharpening shop, and I am about half through already. Instead I have used metal working center reamers as drills, which work great, and normal metal drills, but start with small holes and open them up with a sucession of slightly larger drills. I bought some cheap files from Harbor Freight, and they cut fast and last well. One thing though, don't use much pressure and just let the tool cut at its own rate to get a smooth cut. The fiberglass cuts quite fast, like wood.
My hull came with the gunports cut out with a laminate trimmer, and all I had to do was square the corners with a square file. The corners are not exactly 90 degrees, so some care and a triangular file were needed to get sharp corners. Fitting the bowsprint looked to me like the trickiest job to be done on the hull. You have to make a 7/8" hole right through the stem, rail, and fore deck of the bow at the right angle for the bowsprint to lay flat on the bowsprint rest, while fitting into the bowsprint bits at it's correct location on the deck and keeping the bowsprit lined up with the centerline of the hull. The directions have you install the fore deck and bowsprint rest first, but are silent about how to get the hole cut accurately. The first thing that occured to me was that the fore deck would block access and visibility to the work area and greatly complicate the operation, so I decided to fit it after the bowsprit was in position. I installed the bowsprint rest with #6 hex head sheet metal screws from below, so I can remove the rest as necessary instead of permanently gluing it to the deck. I found some small washers with neoprene bonded to one side to seal the hole. There is plenty of space under the deck to get a socket on the hex head screw, so it is easy to install them even though you can't see them. I think I will use this method with #2 or #4 screws instead of pinning and gluing for all the deck furniture. I like the idea of being able to remove things for modifications, maintenence, refinishing, and especially correcting mistakes. I drilled a 1/4" hole in the front of the prow where I thought the bowsprit should come through, then another coming down from the top of the top rail just to get rid of some material and make less filing. But now, how to inlarge the hole to the right size and angle. I decided to make a 6" rod the diameter of the bowsprit with a tapered end that would rest on the bowsprit rest that I could slide up into the hole to guide my filing as I opened up the hole. This worked very well, and only took me 1.5 hours to do after I made the rod. I had to correct several small problems. The bits ended up too far back from its correct position, so I put a slight groove in the top of the rest to lower the bowsprit end and bring the bits forward. I got the hole slightly off center and had to adjust it and patch one side with epoxy putty. The other thing still puzzling me is that the bowsprit should have been at a greater angle so that it came out farther back on the fore deck. All the parts and positions check with the plans. But the bowsprit rest would have to be 1/2" higher at the front to have positioned the bowsprit correctly. This poses no operational or even aesthetic problems, but mystifies me. xsparsx xbuildx
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Joined Nov 2005
98 Posts
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Check these square riggers out that are ready to sail from the UK... www.rchobby.co.uk go to yachts and check out the HMS Victory etc...ready to go.
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